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how to remove a broken manifold screw(muffler ) (Read 152 times)

danDmen

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how to remove a broken manifold screw(muffler )
04/03/11 at 05:14:58

good morning guys .....well yesterday a was replacing my muffler ..i try slaiding it out but the muffler was pretty tight ...so i start romoving the full muffler ...one of the bolt that hold the muffler to the engine broke in the way out ....i have try whit vicegrips and nothing ...i now the next step is to drill .....but i wan to be sure ... do you have any trick you will like to share...

thanks

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: how to remove a broken manifold screw(muffler Reply #1 - 04/03/11 at 06:13:33 How many turns did you get out? How much metal is poking out? Get some Kroil or wintergreen oil & let those threads soak a while. If you can screw i in any, 1/8th of a turn, then worlk it back & forth & keep penetrating oil in it.
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danDmen YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 43	Re: how to remove a broken manifold screw(muffler Reply #2 - 04/03/11 at 06:18:19 hey thanks .... well is i have like 2-3mm out and it may have 2-3mm in the hole ...but the problem is that mi engine is on the bike ...is a very unconformable position to work on it .
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Trippah

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Re: how to remove a broken manifold screw(muffler
Reply #3 - 04/03/11 at 07:09:16

You are talking about header bolts??
Soak it with penetrating oil ..it sounds like it was turning and then broke?

Depending on LUCk, you can remove the top end while leaving the engine still on the Savage, just lowering it all you can for clearance. I personnally now recommend this route, and taking the top end to a machine shop where, if you have some of the header bolt available, they can weld a bit to it, if that doesn't work see below:

When it goes bad.
One of mine broke, below the surface. I tried drilling and an easy out..the easy out broke also. A year later I found a nice guy with an EDM shop, the only way to get it out. Helped him sell his Guzzi as a thank you. The quote for the work ranged from about $150 to $250., but we working out a much better deal for all involved. Grin

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danDmen YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 43	Re: how to remove a broken manifold screw(muffler Reply #4 - 04/03/11 at 08:33:02 yes men it was turning ok ...and then ...snap! i have like 5mm left on the part of the bolt that broke ...and 2mm little piece showing out ...so i think it may be more like 4-5mm in the hole .... so shut i do this ?? http://www.youtube.com/watch?v=rNgpDYGcMsU&feature=related thanks
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: how to remove a broken manifold screw(muffler Reply #5 - 04/03/11 at 11:19:06 The essential part is to play Nine Inch Nails while you do it. The Devo version of "Head Like a Hole" won't work.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28903 L.A. California Gender:	Re: how to remove a broken manifold screw(muffler Reply #6 - 04/03/11 at 13:02:17 If you got 2mm sticking out, grab it with the vise grips and turn it out. Becareful with those easy outs, quite a few have busted them off in the hole.
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danDmen

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Re: how to remove a broken manifold screw(muffler
Reply #7 - 04/03/11 at 16:44:41

ok guys ....is fix!!!.....fix like back home stile (that is never good).i use the vice grips and nothing ....i drill a beat and a screw remover ...dint work....i did that a couple of times and nothing ...and after almost 8 hours screwing around i got fed up (never good) i drill thru whit a small bit then a bigger one ...and i got it close to 5/16 and the i ram a metal screw in to it and that is it ....she works good ...

she looks more and more like a rat road now and she sound great i cant belive that much noise comes out my savage ...i lose the the big POP!!!at shut off time ...but i gaing so much more whit the strait pipe ...

thanks for all your help ... Grin

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Chopped Senior Member Offline Hurts Like hell when you shoot yourself! Posts: 499 Stafford, VA Gender:	Re: how to remove a broken manifold screw(muffler Reply #8 - 04/03/11 at 17:47:04 well now you have to show us some pics of the darn thing!
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danDmen YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 43	Re: how to remove a broken manifold screw(muffler Reply #9 - 04/06/11 at 06:20:18 is not the original intake manifold screws and muffler clamp ...but they do the job ... thanks for all your help ...
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danDmen YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 43	Re: how to remove a broken manifold screw(muffler Reply #10 - 04/10/11 at 18:11:06 thanks to all ....for the great advice ...
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