exhaust bolts snapped, feeling screwed

[crownpoint]

i am trying to replace the muffler on my 225dx and i just snapped off one bolt holding the header to the cylinder head. the other one is intact but stuck. i tried drilling it out but it is some kind of hardened metal. what is the best way to deal with this??? do i need to remove the head and bring it somewhere to get this retapped? this must of happened to some other people here, right?

[devildog_0431]

Get yourself and a punch and knock it until u get a starter hole etched in so your drill will get some bite. I snapped one off on my V-10 i put in my truck, just punched it and drilled in and easy outted it, should work for you. Is it snapped flush w/ the head ? you could try some vice grips if you have some of the bolt stickin out.

[84honda200s]

if that dont work grind it smooth,punch it,drill it, then retap the hole. ive had to that a good amount of times.

[ceaserthethird]

drill it out , Then buy a " Heli Coil " Kit ... they run from $40 - $100 for a kit

Good luck

[ceaserthethird]

Napa auto parts store has them - Heli Coil Kit's -

[burnoutboy]

I feel your pain mate... just went through the same problem on my 200. Your best option is to get an engineer to get them out. My bolts cost me $25 to get extracted.

[jason 32]

can you weld a new nut to it then un bolt it???? or is it broken off flush ?or in the head-- even in the head you could still get a wire tip in there and build up the metal and weld the nut to it--- if its still hot it will come right out---
shouldn't hurt the alluminum either-- it wont weld to it

[El'Capitan]

happend on my 350x...punched it, then a left hand diamond tipped drill bit. broke the bit but the stud came out./

[crownpoint]

thanks for the advice. i ground down the bolts and drilled and tapped them. it was a pain but its done. tomorrow i'll get some bolts and then go for it.

[DeePa]

that happened on my 200s...i went on ebay and bought another head lol...13 shipped to my door and it worked perfectly.

Mike

[troy]

that happened on my 200s...i went on ebay and bought another head lol...13 shipped to my door and it worked perfectly.

Mike


Happend to me with my ERN snapped both bolts off, had some one try to drill them out, made a freaking mess out of it, so bad i could even bolt the flange to the head. so i bit the bullet and change the head all together. The muffer is on nice and tight and i gained a ticking noise. but it works. i'll fix the noise soon. when there snow on the ground to run my ski doo:)

[crownpoint]

yeah it gets messy pretty quick. i managed to get the muffler bolted on but there is a leak and it doesn't look good. i have some work to do because this engine smokes so maybe when i do the rings and probably rebore it i'll have the guys at the machine shop clean it up.

i like the idea of getting a new head though then getting everything together and swaping the old one out. this trike is starting to become high maintenance, on the last ride i snapped off the shifter lever and came home stuck in first. i've already welded it and now the last 1/2 " snapped off. maybe i'll try to weld it again...

[DeePa]

dotn weld it to the shifter shaft...not worth the aggrivation.

buy a new one. things break after 20 + years