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Message started by SW-Vegas on 08/08/11 at 19:25:25

Title: Buggered Head Bolts
Post by SW-Vegas on 08/08/11 at 19:25:25
Someone tried to install a custom exhaust on this 2002 LS650 I recently took in on trade.  They buggered the bolts into the head, so now the bolt on one side sticks out and they have a wire wrapped around the bolt and tied off to the exhaust pipe.  How do I start restoring it?  I don't have the tools or the knowledge to pull the jug, but it looks like it will take a trip to the machine shop at a minimum.  Maybe a replacement head.  Anyone have a used head for sale?

Title: Re: Buggered Head Bolts
Post by verslagen1 on 08/08/11 at 20:17:56
put helicoils in.

Title: Re: Buggered Head Bolts
Post by Gyrobob on 08/09/11 at 05:00:56
Assuming you are from Vegas, I'm sure there are some machine shops/bike shops/racing shops that can do helicoil work, like Vers mentioned.  The shops around here in Atlanta charge maybe $20.

One thought,.... they might not have the capability to do a metric helicoil.  Do you care?  It wouldn't be a showstopper for me, but I would rather have the replacement hole match the original hole. You might have to make that decision.

Title: Re: Buggered Head Bolts
Post by drums1 on 08/09/11 at 05:14:14
$20 per helicoil?? That's amazing. I think I'll move to Atlanta.
Metric? Standard? I don't think the motor will know or care.
You might post in the Marketplace section--someone may have a used head. Or maybe try EBay.

Title: Re: Buggered Head Bolts
Post by Gyrobob on 08/09/11 at 05:57:03

3620273F2163520 wrote:
$20 per helicoil?? That's amazing. I think I'll move to Atlanta.
Metric? Standard? I don't think the motor will know or care.
You might post in the Marketplace section--someone may have a used head. Or maybe try EBay.


Several years ago I took in a lawn mower head from an old motor I had inherited that had munged-up spark plug threads.  It was $14 and change, so I am guessing $20.  Okay, maybe $30.  

Hell, you can buy a whole helicoil repair kit on ebay for $30!!

Cheaper and way less trouble than a new/used head.

Metric? Standard? I don't think the motor will know or care.  The motor won't, but I do,... some.

Title: Re: Buggered Head Bolts
Post by drums1 on 08/09/11 at 06:05:32
Well ya, the head's gotta come off either way, so I guess cheaper is better. I just know it would cost a dam sight more than $20-$30 to have a helicoil done here in Wisconsin. $100 maybe. They are all about labor dollars. I had a helicoil done on one of my head bolts (or should I say, a "sleeve") It came loose with all the vibration, or maybe wasn't properly installed in the 1st place--point being, it started leaking oil around the head. ( I just had the head gasket done) He ended up drilling it all the way through and putting a nut on the bottom, sealed with locktight.  

Title: Re: Buggered Head Bolts
Post by Gyrobob on 08/09/11 at 06:07:07

3A2C2B332D6F5E0 wrote:
Well ya, the head's gotta come off either way, so I guess cheaper is better. I just know it would cost a dam sight more than $20-$30 to have a helicoil done here in Wisconsin. $100 maybe. They are all about labor dollars. I had a helicoil done on one of my head bolts (or should I say, a "sleeve") It came loose with all the vibration, or maybe wasn't properly installed in the 1st place--point being, it started leaking oil around the head. ( I just had the head gasket done) He ended up drilling it all the way through and putting a nut on the bottom, sealed with locktight.  


Are you sure the head has to come off?

Title: Re: Buggered Head Bolts
Post by drums1 on 08/09/11 at 06:11:51
To do a helicoil for a head bolt? I would think so.....

Title: Re: Buggered Head Bolts
Post by Gyrobob on 08/09/11 at 06:16:13

786E69716F2D1C0 wrote:
To do a helicoil for a head bolt? I would think so.....


We need some clarification here.  I think he is talking about the exhaust header bolt,.. "Someone tried to install a custom exhaust on this 2002 LS650 I recently took in on trade.  They buggered the bolts into the head, so now the bolt on one side sticks out and they have a wire wrapped around the bolt and tied off to the exhaust pipe."

If he is talking about the bolts that hold the head to the cylinder, yes, the head has to come off.  If he is talking about exhaust header bolts, maybe not.

Title: Re: Buggered Head Bolts
Post by drums1 on 08/09/11 at 06:24:53
Oh ok. I thought he was talking about a head bolt. My bad. Although access is an issue. Is the frame downtube in the way? Not much room to work down there. Head might still need to come off. And most places charge by the hour. Going rate here is $61.00. Parts may only be $30, plus labor, plus the 1-2 week wait to get an appointment. Might be better off DIY at home. Good luck.

Title: Re: Buggered Head Bolts
Post by serenity3743 on 08/09/11 at 06:41:22
I had a header bolt to break off while I was on the Tail-o'-the-Dragon trip last year.  Took it to a shop named Wheeler's 15 miles south of Deals Gap and the mechanic replaced both header bolts with studs and cap nuts without taking much if anything apart.  I think those bolts should have been designed as studs to begin with.  If you've got to fix it anyway........

Title: Re: Buggered Head Bolts
Post by Gyrobob on 08/09/11 at 08:53:52

637562757E79646923272423100 wrote:
I had a header bolt to break off while I was on the Tail-o'-the-Dragon trip last year.  Took it to a shop named Wheeler's 15 miles south of Deals Gap and the mechanic replaced both header bolts with studs and cap nuts without taking much if anything apart.  I think those bolts should have been designed as studs to begin with.  If you've got to fix it anyway........


What was the cost?

Title: Re: Buggered Head Bolts
Post by serenity3743 on 08/09/11 at 09:08:27
I remember the cost was very reasonable, but I don't remember exactly.  Fairly certain it was <$30.

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