Header bolt removal

[Rod G]

Just finished reading the Tech Tip header bolt removal.

I can imagine the anxiety associated with removing a broken bolt, but am curious just how many owners have experience this?

Is it frequently the problem?  I guess it has a lot to do with the time the bolts have been there.    Rod G

[gsxbarmy]

Certainly in the U.K. it is possibly because we have wetter colder weather than the Southern Hemisphere in general. It tends to happen more on the older bikes where headers may not have been removed and the bolts react with the head (stainless plus alloy is not a good mix!) and that Suzuki never put nickleslip on the bolts at the factory to stop that.

[Del]

I know that I had to drill 2 out on my K2 - bolts are made of toffee

done hunners on Kawasaki's and never snapped a stud

[Red Biker]

I've Just done mine last week, took me 4 hours to remove the 8 bolts, slowly catchie Monkey style.
It was quite nerve racking when you consider the consequences!

This time next week they'll be Black so obviously worth it in the end 

[Rod G]

I'm with you Bro!!   Given that everyone knows about galvanic corrosion, how crazy were Suzuki putting SS bolts into an alloy head without protection??  Built in obsolescence!!!   

[Mrg]

yes ive started to soak them in oil as ive got to do this soon ... ive got a new set to put on the bike for the summer and I am dreading this job 

as far as I know  they never been taken off ... the set that is on the bike now

[froudy]

Plus Gas penetrating oil and lots of it.
I knock a 12mm multi point socket over the whole head of the Allen bolt and undo with 1/4 drive ratchet for ease of access.
The shock of knocking the socket on can help free the bolt too.

Done loads now..Some you get lucky and some you don't.
If at ANY time during removal it gets tighter and squeals, spray more Plus Gas on it and take it back in a little...Then try again

Good luck!

[gsxbarmy]

I agree with Froudy - Plus Gas is brilliant stuff for this.

Also read this article

http://gsx1400owners.org/forum_test/index.php?topic=317.0

[Rufus]

I just removed my headers and sheared off 4 of the 8 bolts 
But it "only" took 6 hours to drill one of them out.
The rest about an hour each 
Amazingly I re-tapped the threads and apart from one being a bit crap, they are all ok.
It was the stock exhaust, don't know if the bolts were stock, they were stainless.

Next I'm off to track down and have words with the dimwit who soaked the front sprocket in Red Loctite!

[gsxbarmy]

I just removed my headers and sheared off 4 of the 8 bolts 
But it "only" took 6 hours to drill one of them out.
The rest about an hour each 
Amazingly I re-tapped the threads and apart from one being a bit crap, they are all ok.
It was the stock exhaust, don't know if the bolts were stock, they were stainless.

Next I'm off to track down and have words with the dimwit who soaked the front sprocket in Red Loctite!

Are you sure the front sprocket isn't orange loctite as that what Suzuki apply. But if it is red loctite Rufus - good luck!!

[Cykik]

I took my original headers off (k2) soaked for a week in plus gas, moved oilcooler out of way &  all header bolts came out ok, so there is hope!!. Just be gentle  removing bolts..

[Rod G]

FWIW.  I was taught that with suspect, corroded bolts to torque them up a fly fart until they crack the bond then undo them.  I absolutely agree with pre-soaking for as long as can be allowed prior to removal. 

[gsxbarmy]

FWIW.  I was taught that with suspect, corroded bolts to torque them up a fly fart until they crack the bond then undo them.  I absolutely agree with pre-soaking for as long as can be allowed prior to removal. 

I agree that is one approach with which I agree - but I wouldn't like to try it on header bolts, as essentially you have stainless bolts into an alloy head - I'd be just wary of stripping the thread in the head myself.

If I was going to do it though, I would apply some heat around the bolt first to allow the alloy to expand a little, then if the bolt wouldn't move, try a socket on an impact driver to try breaking the "lock" that way.

All after a liberal soaking in Plus Gas (preferably) or WD40 for as long a period beforehand as possible!!!

[Mick_J]

If you have a diesel car, diesel is a fantastic penetrating oil, stinks a bit but so does plus gas.

[gsxbarmy]

Hmm that's a new one to file away