Stupidity, snapped two bolts on 85 200s

[DeePa]

First, id like to say hello to everyone as this is my first time posting on these boards. I recently regained intrest in the old 85 200s atc thats been sitting in my garage for longer than ive been alive. I am currently trying to fix it up, although it runs good and strong, just needs a little tlc and maintence to get it back in shape.

A few years ago, i tighetend the nuts which hold the exhaust header onto the engine. Being young and stupid, i decided to crank them as tight as possible, making one of them snap off. The bolt which comes out of the engine block is now about half the size and is of no use. I swore a few times and just let it be with a little noiser trike than before.

A few days ago, i looked at the bike and was like, im going to go buy a new front tire and get it running again. I figured out how to get the tire off, went to the local tire shop, and had a new one slapped on the rim for 65 bucks. Note that 2 of the same tires cost 70 total 8 years ago when my dad replaced the rear tires. When finally reinstalled the tire, i did the same thing as i did to the exhaust header mount. I over tightened ione of the nuts and snapped the bolt again. Its one of the 4 bolts which hold the axle onto the fork on the non brake side of the rim. Im sure you all get what i mean, and if you dont, i can get some pictures.

Now, where i need help. Are the bolts im talking about pressed into the engine/fork or are they screwed in? What would be the proper procedure in fixing this problem? Should i leave it be? I have a friend who owns a little machine shop, and im sure he could drill out the bolts, and retap the holes so i could thread another bolt in there and attach it like before. Please let me know what you all would do.

On another note, i ordered new brake pads/shoes off of ebay, and im about to order 2 new brake levers because the ones i had snapped a while ago, and ive just been using the foot brake. DO you think a slightly bent rear axle is worth replacing? How hard are the brakes to work on? I ordered the repair and service manual on a cd off of ebay, and i cant wait to check it out when it finally comes in.

One more question...I need a new air filter...I found a K&N one for 40 bucks free shipping to my door...is that a good deal? Should i just find a cheaper one?

Thanks,
Mike

[hotroddal]

well he exhaust header bolts just screw into the cyclender, and i think its the same with the forks, and yes buy that k&n there awesome air filters, and a slightly bent rear axle will cause damage in the long run, because its a straight axle and it will ware out the rear axle bearings, but if its just a slight bend i wouldnt worry about it till the rear axle bearing are shot then i would try to find a used axle to put back in there, and the barkes are a piece of cake to work on. o ya and welcome to the board!!!

[350x'inNY]

I've had one of the studs break off for my front axle holder on my 350X. You can still buy them from HONDA. I am assuming this is what you are talking about. I just took a pair of vice grips and backed out the broken one, and replaced it with a new one.

Bruce

[patblkwell]

Hey 350xinNY, are you talking about the 4 small bolts that hold lower fork onto the front axle? I have one broken on my 250es and was wondering if I had to buy a new lower for end...didn't know those bolts could be backed out? I'd think that mine would snap if I tried to back it out...

[patblkwell]

[QUOTE=350x'inNY]I've had one of the studs break off for my front axle holder on my 350X. You can still buy them from HONDA. I am assuming this is what you are talking about. I just took a pair of vice grips and backed out the broken one, and replaced it with a new one.

Bruce

Hey 350xinNY, are you talking about the 4 small bolts that hold lower fork onto the front axle? I have one broken on my 250es and was wondering if I had to buy a new lower for end...didn't know those bolts could be backed out? I'd think that mine would snap if I tried to back it out...

[crackshot]

you don't need to apply gorilla strength to nuts and bolts people!

[DeePa]

thanks for the help everyone, i am going to try to find out the part #'s for the studs i need. I figure im going to order 2 for teh front axle part and 2 for the exhaust header part, because if one went, the other will probably go eventually.

Thanks again,
Mike

[350x'inNY]

Hey 350xinNY, are you talking about the 4 small bolts that hold lower fork onto the front axle? I have one broken on my 250es and was wondering if I had to buy a new lower fork end...didn't know those bolts could be backed out? I'd think that mine would snap if I tried to back it out...

Nope.... you don't need a complete lower, you can replace those studs. They are "double threaded". The dealer had some generic ones, but I had them order the correct one from HONDA. Think it was like a $1.20?

Yep.... soak her up with some WD-40 and let it soak in a bit. With bolts like that, sometimes try tightening a hair first to break it loose, then back it out. Mine came right out. It was on the Go-Go girl.... she's been rode hard :naughty: and wasn't maintained that great before I got her.

[patblkwell]

Oh ok, good deal. I'll have to try that one day. You just used a standard vise or what? What did you do to lock the new bolt studs in place?

[bigredhead]

so those suckers do come out !!!! cool !

Thanks for that bit of info NY !!

My 250 SX has a similar setup.. 4 bolts that hold the axle on the forks on the right side.. and one of them is partially stripped !!!

[350x'inNY]

Oh ok, good deal. I'll have to try that one day. You just used a standard vise or what? What did you do to lock the new bolt studs in place?

I hand tightened it in as far as I could, then I double nutted it and tightened the outer nut as far as I could with a wrench. Then backed the 2 nuts off, put the bracket on, tightened the four studs and been ridding it ever since!

Bruce

[chris200x]

Here's a tip: Don't tighten the bolts down hard!

Yea that's news to me also, One of my threaded studs are broke too.

[DeePa]

update...one new front axle stud and one new exhaust header stud will be coming in on thursday.

New problem...getting the broken exhaust header stud out. Tried with vice grips, they just slipped. I took my dremel and cut two flats on the bolt, and the vice grips get a great hold, but it still wont freaking budge. I am soaking it in some **** to loosen it up now, and im going to try again tomorrow.

ANyone have any ideas to help?


edit...the front axle one came out just fine

[patblkwell]

Hey DeePa, where did you order your front axle stud from? I need to get one for mine..

[DeePa]

honda dealer took care of me, only cost like a buck

ill give you teh part # off of the receipt tomorrow

[patblkwell]

OH ok cool, I guess they are all the same size for the front axles. I have a 250es...I'm sure they're the same.

[DeePa]

ok, its either one of these two numbers

90031969680 or 92900060250E

one is for the front fork stud and one is for the engine/exhaust header stud.

[DeePa]

guys, i cant get the engine stud out to save my life...whats th ebest techinique to do so? Its now flush with the cylinder head (at least thats what i think it is)

please help me out,
thanks,
mike

[Rex Karz]

Dude be very careful here

What you need to do at this time is drill a hole in the stud and use an easy out to remove it.First soak with lots of penetrant for at least a day. Very carefully get a tiny drill to start a hole exactly centered on the stud. The act of drilling a hole in a stud allows the stud to shrink a little. Then if you can, insert an e-z out and twist it out. If you have to, drill it a little larger. Be sure to miss the threads, take your time! Be sure your drill bits are brand new, you want to take every advantage you can. If you think it will help, use a center punch to start your first drill pass. Use a little oil when you drill. Another trick is to heat up the whole cylinder with a hair dryer and use ice or freeze spray to try and shrink the stud. That works better on the larger studs, though. But that's going overboard, maybe not if it saves you a cylinder. When you get the stud out, chase it with a tap before you put a new stud in. GOOD LUCK
L8

[DeePa]

thank you very much, im sure im going to need all the luck ing the world. What kinda of drill bits would work best for this? How hard is the cylinder head to take off? The dealer said he would take care of it for me, only if i take him just the cylinder head, and nothing else.