snapped bolts on engine block for honda cbr600f motorcycle.?

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kane116

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i tried to change the downpipes on my honda cbr600f 2002 plate motorcyle for new ones but all the nuts holding the old downpipes on sheared off leaving about 10mm of bolt sticking out the engine block. its not enough to hold the new ones in place. i have been told the bolts need to be drilled out and replaced. is this true and do i have any other options? how much will it roughly cost?
 
Because the bolts are protruding, you might be able to remove them without resorting to radical means. Start with liberal amounts of penetrating oil and let it work overnight. Then TIGHTLY grab the broken bolts with vise-grips. With luck you might be able to loosen them...

A variation on this method is to file/grind a couple of flat surfaces of opposite sides of each bolt to give the vise-grips a better bite.

If this doesn't work, you can purchase a bolt extractor (aka an "easy out"), from your local auto-parts store. They are not very expensive and usually do the job.

If you drill out the bolts you will damage the bolt threads in the head so you will also have to purchase a set of taps to cut new threads. This should only be your very last resort.
 
Ok I have some good news,go to AutoZone and tell them you need to tap out whatever size bolt that is,i think it's 10mil not sure,but you wil need a small drill bit and the tap.What happens is you drill a small hole in the center of the broken bolt,then take your tap and since it is left hand threaded when you get it tightened it will begin to turn the bolt counter clockwise thus removing it,it will take only 15-30 minutes,just take your time and turn the tap slowly and if it feels time too much resistance the you may try a bigger tap,just try to keep it centered and a slow steady turn.And the tap is only around 4 bucks.
 
pretty small for an easy out, which is what Donald is talking about, you break that tool steel off in there and you just shot yourself in the foot, now any chance of drilling and re tapping are gone, your best bet is taking it to a pro, or risk buying a new head, using heat and welding a nut to whats left of the stud is the best option but with aluminum you better know what your doing, or your buying a new head, if I have success with that technique, you'll get out for around $200 to $300, if I have to drill and tap probably closer to $800, but I have a lot of really cool tools just for broken bolt removal, so I rarely have to go down that road.
 
sometimes they come loose with penetrating oil, (like "liquid wrench") a pipe wrench and a little heat (if they're really stuck).
OH Yeah...... and a lot of patience.
Sometimes they seize up so badly that you HAVE to drill them out.
 
Ok I have some good news,go to AutoZone and tell them you need to tap out whatever size bolt that is,i think it's 10mil not sure,but you wil need a small drill bit and the tap.What happens is you drill a small hole in the center of the broken bolt,then take your tap and since it is left hand threaded when you get it tightened it will begin to turn the bolt counter clockwise thus removing it,it will take only 15-30 minutes,just take your time and turn the tap slowly and if it feels time too much resistance the you may try a bigger tap,just try to keep it centered and a slow steady turn.And the tap is only around 4 bucks.
 
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