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Pulled the exhaust off my Katana and three of the eight bolts sheared off in the head. I have a decent amount of access to them but am unsure how to go about removing those remnants. I've actually never sheared off a bolt befoe, so I am awfully lost on this. My current idea was to heat it up with a torch and tap in an EZ-out or something. Maybe drilling a hole in it, JBwelding a small bolt into it and then heat it up and try removing it that way. Any ideas for me?

If you are not in a big hurry to remove them, spray them with wd-40 over and over a few days, tap on the broken bolt and if you have enough bolt left use a pair of vise grips or small pipe wrench and work the bolt back and forth. Keep spraying as you work the bolt. I don't have a torch so I can not tell if that is the way to go. Hope that you are able to remove them, it is a job.

Yeah... they're all snapped flush to the head. I'm hoping I can get an EZ-out in there.

Your going to have to drill them to get an ez-out in there, so get a lefthand drillbit and with the soaking and what-not, you may get lucky on a few of them. Even if you don't take any out with the drill bit, your no farther behind the ball than before and you can work the ez-outs from there.

Alright, picked up a bolt extractor kit from Sears. Looks to be a combination of a left-handed drillbit and an EZ-out. You drill in (CCW) for a bit, tighten a collar down into the bolt that looks like an EZ-out, then drill in more and pull out.

The diagram makes it look easy. I'll be soaking the bolts in PB Blaster, tapping them with a pointy thing and a hammer, then spraying again, for the next day or so. Then I'll get the bolts real hot and go to town.

if you have access to the nut rather than the bolt. You might want to try using a nut splitter. Sears has them for under 20 bucks. It is however a destructive method in that you will have to get a new nut (Bolt might survive though).

K

kar_the_terrible wrote:if you have access to the nut rather than the bolt. You might want to try using a nut splitter. Sears has them for under 20 bucks. It is however a destructive method in that you will have to get a new nut (Bolt might survive though).

K

Yep, I have access to the nuts... they're sitting on my workbench while the threaded part resides in my cylinder head.

As for my attempts, well, I shattered two of the Sears parts trying to remove one bolt. Been drilling away with my masonry bits at the last two bolts so I can get a screw extractor in there, but no luck so far. I'm probably going to cut my losses, pull the head and have someone else do it.