Bummed... Snapped off two hex bolts to the carb intake

Yes... not a good day yesterday. As carefull as I was two out of the eight bolts snapped off leaving just a nub. Was trying to replace the rubber carb joints. Need to find a way to get them out. Tried filing the nub square so I could get a small wrench on it but so far no luck.

Think the metal is too soft. Will try some other things later today. Wish me luck

Rob

 

If you have a mig stick a non plated nut on the nub and center weld it. The heat does wonders for loosening the threads up. Good luck . I just went through the same thing (4) . Had to pull the head and get a machinest to do it. Those bolts have to be the sorryest steel ever made.

 

Me? I'm taking it to the machine shop up the street that pulled my broken exhaust studs out. WELL worth the $25. I'm not messing with that, nope, that head/base is something you don't want to mess up. Unless you really know what you are doing, you are probably going to make it worse by trying to fix.

 

I was taught to loosen stuck screws bolts etc, to tap (not to hard) with a good pliers, not a hammer, straight into the screw on the end of the tool you are using, if that makes sense, use a little pressure turning and they generally come out. Its the only way I could have gotten the p/u coil cover off and carb bowls without stripping the head of the screws, on my bike that had sat for 3 years.

 

The truly sad part about the Intake Manafold Cap Screws being of such poor quality and seizing in the Head; is that removing the Manifolds is a necessary Maintenance chore. You have to be able to remove the Manifolds at some time and face the dilemma of the seizure problem.

If the Factory had treated the fasteners with anything to prevent the two metals from seizing ... life would be so much easier for the owners and those working on these bikes of ours.

The problem is so common that those who don't find theirs seized or have some treated by an PO to prevent the trouble are the exception ... (it seems.)

 

yeah still no progress... I may end up pulling the head... this blows.

Rob

 

I am so scarred by the last experience, that on the latest 900 project, I havn't even attempted to remove them.

 

Sorry about your luck dude, Yeah i got lucky that all the intake bolts came out nicely for me, though all the screws in my carb pack gave me a hard time, but got them out to.

I plan on replacing every bolt and screw with stainless allen's. :idea:

 

Be sure to use anti-seize.

 

yeah sure wish Yamaha used it.. Judging by the material on the others that came out almost looks like they used a thread loc on them. However it could just be age and rust.

Rob