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Old 07-10-2009, 03:58 PM   #1
TiemannR6
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Broken head bolt/stud!!! HELP PLEASE

i have a 03 r6 with about 29k miles on it. i was pulling off the header and one of the studs broke off flush with the head.
Tried drilling it out but no such luck.

so were going to pull the motor and take a better look at it, might have my friend machine it at his shop. have any suggestions? or should i do anything while i have the motor pulled??
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Old 07-10-2009, 04:37 PM   #2
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Have you tried extractors?
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Old 07-10-2009, 04:47 PM   #3
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tried a easy out and it broke.. luckily it came it.. maybe i'll try a left hand drill bit??
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Old 07-10-2009, 04:48 PM   #4
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it's a cylinder stud. you may need heat
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Old 07-11-2009, 01:15 AM   #5
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^^^^ thats what im thinkin too. torch it
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Old 07-11-2009, 02:02 AM   #6
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Quote:
Originally Posted by burnboy View Post
it's a cylinder stud. you may need heat

almost everytime.
and cover them in releasing fluid the night before too, that can help but heat is the key
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Old 07-11-2009, 02:39 AM   #7
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Old 07-11-2009, 02:42 AM   #8
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in east india?
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Old 07-11-2009, 02:51 AM   #9
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Old 07-11-2009, 03:03 AM   #10
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Worse comes to worse and you wind up pulling it talk to Richard or Wayne at RW Machine on the northside. EDM that fugger out!!!
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Old 07-11-2009, 12:21 PM   #11
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Old 07-14-2009, 12:28 PM   #12
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word on the welding. The tack will only stick to the bolt, it wont stick to the head (aluminum)..We do this all the late model chevy v-8s manifold bolts....Welt a good sized bead onto the end of the bolt and twist it out with a pair of vice grips.
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Old 07-14-2009, 12:46 PM   #13
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Old 07-15-2009, 05:58 PM   #14
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i got it out.. thanks for the help.. and FYI although most of the time welding a nut to it works.. this wasnt one of those times.. welded a nut to it twice and it still broke off. i soaked it with penatrating oil and even let it cool down completely after welding so the bolt wasnt expanded.. drilling and beating the FK out of it with centerpunches was the only way.. oh well.. my first "motor swap" in a bike!
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Old 07-15-2009, 06:07 PM   #15
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Old 07-16-2009, 10:58 AM   #16
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i had a machinest and one of the best welders around with me and couldnt thread the bolt out. i've never seen a bolt so stubborn yet so weak that you could barely twist it and snap it off.. bolt/nut same principal. welded the nut to it when there was still 1/4-1/2 inch of thread sticking out. we slipped it as far on the stud as would could where it was touching the head so it would have less stress on the end of the stud.
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