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  1. #1
    SideFX's Avatar
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    Question How 2 remove broken exhaust2manifold bolts? XP

    Working on an older ski here, a '94 xp, lots of fun when it gets rough out.

    However my problem is that the two front exhaust bolts from the purple pipe to white manifold have sheared. Rear ones are ok.

    Realizing that the bolts be stainless? and the manifold cast?? I need some advice on what works best and how careful to be.

    Thank you.


  2. #2
    You could try to center peen the sheared bolt threaded section--drill--and use an EZ-out on it after heating it with a Propane Torch,, but if you don't get it drilled dead center then the EZ-out will be offset and you will screw up the threads in the Manifold. --Take your time doing this.

    Another safer method is to take it to a very good welder who can build up a bead on the sheared threaded "stud", and then back it out using vise grips. The heat from the welder will thermally break down any lock-tite used.

    .. or you can just buy a good condition used one---plenty out there.

    In any case, when you put it all back together, use all new Rubber Bushings in the Exhaust Bracket mount holes which is why it probably loosened up in the first place. The Bushings crack over time and give too much play to the vibrating mass of the Pipe. I've seen this time and time again... Good Luck

    ---DvD

  3. #3
    SideFX's Avatar
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    Will do. Thanks for taking the time

  4. #4
    SideFX's Avatar
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    F*K
    I failed...................................
    Found replacements on Ebay cheap cheap. (Thank God)
    gadssssssssssssssssssssssssssssssssssssssss

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