I hit the broken-stud jackpot!

[Pete.]

Removed a set of Bandit headers yesterday - how many of the bolts snapped just below the head you think? All bloody eight of them!

Better do the lottery this week my luck's sure to turn sometime soon.....
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[DrDonnyBrago]

I do not envy you at all .

[h00dwink]

started taking my SR125 apart yesterday. it would appear that metal turns to cheese when left to chill out.
sheared an exhaust bolt. rounded off plenty of allen bolts and mounting nuts.
nut splitting tool in post to get some revenge.
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Sahf East Winnah 4LYF
https://bikepics.com/members/h00dwink/00sv650s/
www.youtube.com/h00dwink updated regularly

[pepperami]

[wilz1234]

It's a sign.....



...that you never really needed that exhaust anyway
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RS50 - ZXR400 - ZXR 400 - ZX7R - Bandit 600 - NTV 650

[Pete.]

[Nick 50]

Pro-bolt do lots of Titanium bolts for all-sorts, except studs/nuts (AFAIK).

Does anyone know why not?

I think it can be done:

https://titanclassics.com/images/small/full%20exhaust%20manifold%20kit.jpg

That's a Titanium set for a Pre-90's Mini which is £35.

I would happily pay £50'sih for a Titanium set knowing (or hoping) never to have the problem.
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Current Bikes: ZX7r 97 (Black Beauty), VFR400 NC24 (The banana)
Previous Bikes: Aprilia Tuono 03 (The Beast), CBR600f (97)
First bike: A GZ125 Lemon.......

[Pete.]

Titanium isn't wonder-metal. Studs and bronze/aluminium bronze nuts are best. I quite like the Yamaha idea of round nuts on the studs that seem to be able to resist a frozen joint by covering the whole of the thread. Putting a steel bolt in an ally head and exposing it to road salt seems a bit like lunacy to me.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Frost]

These days i wire brush the shit out of them, give them a drop of penetrating oil and leave them overnight. The next day i start the bike up and get the headers as hot as they'll go before attempting the nuts. I've also been known to whack them with a hammer first in the hope of losening them! When it comes to undoing them i like to do it with a breaker bar and a smack from a hammer. In my mind i imagine the stress crack in the stud spreading the whole time the torsion is on them and imagine that the sharp tap frees up the friction stuck thread
Reassembly involves a fuck tonn of copper grease

[Pete.]

Bandits use socket caps, not so easy to get the shock into them nor crack with a breaker. This bike is peculiar because it's clearly not been winter-ridden and the finish on the engine is still quite good for a 1996 bike so you would expect it to free up nicely but those bolts were solid in there. Couldn't start the engine as the exhaust was off and I fancy keeping my gonads.

Last two Bandits I pulled all the bolts without breaking a single one.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Pete.]

Here's the remedy - or the start of it anyway:

https://www.bikechatforums.com/viewtopic.php?p=3405144#3405144
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[wilz1234]

Studs are normally made of plain old steel because when they snap, they're a lot easier to drill out/remove. Imagine having to drill out a 12.8 steel or titanium stud.

[Frost]

So you drill the hole down the centres, then widen it, then use a thread tap to clear out the thread?

What about ones that snap off flush?

[wilz1234]

I tend to find that 12.8 hardened bolts knacker drill bits very quick because they're kinda...um....hard
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RS50 - ZXR400 - ZXR 400 - ZX7R - Bandit 600 - NTV 650

[Pete.]

[Nick 50]

[Frost]

The problem with titanium is that though no indestructible (especially at the piss poor grades used in motorcycle parts and accessories!) It will still be tough enough to make it a total twunt to drill out or otherwise work with should it break.