Now what? stripped nut and broken bolts?

Well, I decided after getting the bike....I should change the oil.

No biggie. Drained the oil.....went to take of the filter cover. WTF?!
The nut is stripped. Of course, I need to order one.
BUT...the catch is.......I can get to the bolt because my 4-1 exhaust is in the way. I decide I should take it off.

So I soaked the 8 nuts holding the exhaust in place with WD-40.

All but 3 came off with ease. 2 snapped....with hardly any pressure. The 3rd just spins in place.

Now what?

Are those threaded posts just pressed in?

 

Ugh.......they're screwed in........ :cry:

 

Yeah....I freaked out before I investigated.

No worries.

This is my first "job" on the bike.......and I knew something would break. guess I'll have to take a bike vacation until I get the parts.



I'll send you a PM.

 

Those studs will have to be drilled out & re-tapped, you might have to remove the head & take it to a machine shop $$$$$$$$$

 

they didn't break at the head.......they broke right after the nut....so there's quite a bit of lug hanging out.

 

I was going to replace them all, but it looks like most of them want to stay where they are.

I got one of the broken ones out.....but the other one isn't moving at all.

What can I do?

 

Heat is your friend on those guys. The aluminum expands more than steel. You can even quench the stud after you get the boss in the head good and hot (although I never needed to).

 

Never-mind...again, I ask questions before I think.

Can I re-assemble the bike sans one lug being attached and drive it?
If worse comes to worse.....I'd have to drive it to work....to weld a nut to the broken stud for more turning power. Vice grips don't seem to be able to get a good grip on it as is.

 

Hey Josh get yourself some PB Blaster to spray on those studs and when you go to remove them tighten them slightly just til they move this will aid in loosening them without breaking them off. HTH lhttp://blasterchemical.com/display.cfm?p=50003&pid=4

 

Thats why I am glad my Honda has an oil filter can instead of a housing. The oil changes on this bike go as smooth as silk. I was in the same situation I went to change the oil in my xj and what did I find? A stripped oil filter housing bolt the PO decided not to tell me about.

 

That is that plan. PB blaster....see if it moves.......then apply heat......see if it moves.......then either weld a nut to the stud to crank on it or weld a threaded stud to the broken stud.

I'm not going to remove any of the remaining studs. I don't want to break anymore. I'll just clean up the existing ones....and be done with it.

Worse case, last resort....is to cut the stud off and drill it out and probably helicoil. I hope it doesn't go that far.

 

Results: No go. The stud will not move.

I tried the blaster spray.......tried heat. Nothing.

I can't really get a good grip on the thing...so that doesn't help.

Sidelined.

 

Well, after wrenching on the stud for a few days.....it finally snapped off below the head screw boss.

I tried an easy out, but the thing would not move.
Seems like either it welded itself in place or the PO messed it up.

I got the replacement parts from Chacal, and got it back up and running. sans one exhaust stud.
Nice to know I don't have to mess around next time I do an oil change.

I figure I'll wait until the riding season is over before I figure out how to drill the stuck stud out.....or take it somewhere to have it removed.

Probably have to pull the engine, eh?

 

What size are those studs? I may have an old carbide drill I can send you. I hang onto chipped carbide drills for just this kind of purpose. It makes drilling them out a lot easier.

 

6mm