Muffler Escaped

undertulsa · 06-25-2009, 04:21 PM

Ok guys, i drove across town and the muffler bolt coming out of the engine sheered off, how can i get that bolt out? If you can believe it these bolt were checked and they were tight till the ride, so i didnt locktite them.

honda scematics show that the bolt has threads on each side but how do you screw it out of the engine. Fortunately, the muffler just fell off lost one bolt and the gasket and the pipe joint laying on the road somewhere. I think i can order them at honda store cheeply but the main problem is getting bolt out.

have screw out small enough but what is the normal way to remove the bolt with threads out of the engine that was sheered off?

FastDoc · 06-25-2009, 05:04 PM

You can use a screw extractor. A good trick is to use a reverse drill bit to make the pilot hole. Often you get lucky and the stud comes out just like that. CONSIDER taking the bike to a machine shop and letting them do it for you, hopefully while you wait. Cheaper than fixing the head if you screw it up... :roll:

Cal25 · 06-25-2009, 05:15 PM

Is the stud broke flush with the cylynder? If it is sticking out a bit, you might be able to un screw it with some pliers.
Or maybe use a dremel with a very small wheel on it to cut a slot in it and use a screw driver to remove it?
The gasket and flange are simple enough to pick up at a Honda shop as you suggested.

FastDoc · 06-25-2009, 05:21 PM

Good suggestion on the slot with a sawblade or a Dremil. I've gotten away with that trick a few times.

What do the Chinese make these parts out of anyway? Stale cheese?

FastDoc · 06-25-2009, 05:26 PM

Look what I found!

http://faq.ninja250.org/wiki/Bodywork_%26_Frame

chrism1 · 06-25-2009, 05:58 PM

Same happened to me.I think because the pipe system is mounted rigid.A rubber hanger helps alot.The stud was broke flush.Bought a diamond tip dremel bit and picked away.I then drilled and retapped both the next size larger and redrilled flange to match....nice and strong now.

undertulsa · 06-25-2009, 08:16 PM

My hillbilly brother got the bolt out !!! without hurting head, pair of vice grips!!! Now honda has to order 10.00 of parts and ill be back in business. red locktite this time on the muffler bolts.

:roll:

Cal25 · 06-26-2009, 09:27 AM

Alrighty! Glad it worked out well.

06-25-2009, 04:21 PM	#1
undertulsa Join Date: May 2009 Posts: 219	Muffler Escaped Ok guys, i drove across town and the muffler bolt coming out of the engine sheered off, how can i get that bolt out? If you can believe it these bolt were checked and they were tight till the ride, so i didnt locktite them. honda scematics show that the bolt has threads on each side but how do you screw it out of the engine. Fortunately, the muffler just fell off lost one bolt and the gasket and the pipe joint laying on the road somewhere. I think i can order them at honda store cheeply but the main problem is getting bolt out. have screw out small enough but what is the normal way to remove the bolt with threads out of the engine that was sheered off?
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06-25-2009, 05:04 PM	#2
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	You can use a screw extractor. A good trick is to use a reverse drill bit to make the pilot hole. Often you get lucky and the stud comes out just like that. CONSIDER taking the bike to a machine shop and letting them do it for you, hopefully while you wait. Cheaper than fixing the head if you screw it up... :roll: __________________ Happy to serve.
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06-25-2009, 05:21 PM	#4
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Good suggestion on the slot with a sawblade or a Dremil. I've gotten away with that trick a few times. What do the Chinese make these parts out of anyway? Stale cheese? __________________ Happy to serve.
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06-25-2009, 05:26 PM	#5
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Look what I found! http://faq.ninja250.org/wiki/Bodywork_%26_Frame __________________ Happy to serve.
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06-25-2009, 05:58 PM	#6
chrism1 Join Date: Sep 2007 Location: Bevely Hills,Florida US of A Posts: 138	Same happened to me.I think because the pipe system is mounted rigid.A rubber hanger helps alot.The stud was broke flush.Bought a diamond tip dremel bit and picked away.I then drilled and retapped both the next size larger and redrilled flange to match....nice and strong now. __________________ Lifan LF200GY-5
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06-25-2009, 05:15 PM	#3
Cal25 Join Date: Feb 2008 Location: Terrell and Grapevine Tx. Posts: 1,585	Is the stud broke flush with the cylynder? If it is sticking out a bit, you might be able to un screw it with some pliers. Or maybe use a dremel with a very small wheel on it to cut a slot in it and use a screw driver to remove it? The gasket and flange are simple enough to pick up at a Honda shop as you suggested.
	0

06-25-2009, 08:16 PM	#7
undertulsa Join Date: May 2009 Posts: 219	WE got it!!! My hillbilly brother got the bolt out !!! without hurting head, pair of vice grips!!! Now honda has to order 10.00 of parts and ill be back in business. red locktite this time on the muffler bolts. :roll:
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06-26-2009, 09:27 AM	#8
Cal25 Join Date: Feb 2008 Location: Terrell and Grapevine Tx. Posts: 1,585	Alrighty! Glad it worked out well.
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