How to fix my sled?

[DenverR1]

I've got an 05 RT 1000 and I love it. During my last ride the exhaust got really loud. I found that one of the exhaust ports (where the two pipes come out of the engine) was missing 3 out of the 4 screws, so the gasket was sliding out. Well at least two of the screws are broken off in the engine block. Any ideas on how to get them out? I'm obviously not a mechanic, but I can usually figure things out. Thanks for any help.

 

[duallymanca]

If you are lucky you might be able to back the broken ends out with a pick. If that won't work then you need to drill the broken end and remove with an easy out or similiar tool. If the bolt is broken off flush another way is to put a nut over top of it and mig weld the nut to the end of the broken piece. Might want to get that done by someone who has done it before.

 

[snow_knight]

If you can get to them good.. (havent workd on a 1000 rev)... you should be able to use an "ez-out".. to back out the broken bolts.. used them losts of times on our stuff.. any of your local car parts stores should have them..

 

[devilrmk]

If there is anything sticking out, grab em with visegrips. If not use pick first then weld nut method, then drill/ez-out.

If you are lucky you will get it with one of the first 2 methods. Just remember to be careful with the ez-out. They are nearly impossible to drill if you break one.

 

[spring snow hero]

If there is anything sticking out, grab em with visegrips. If not use pick first then weld nut method, then drill/ez-out.

If you are lucky you will get it with one of the first 2 methods. Just remember to be careful with the ez-out. They are nearly impossible to drill if you break one.

I agree not only on the methods, but the order too. do what he said in that order.

 

[DRD]

If you go with the extractors, Snap-On makes a good set that come with left hand twist drill bits. If the broken piece is not too tight in the head the drill bit will often snag it and thread it out

 

[woodies]

buddy told me a trick have not used yet myself but he swears it works break a end off a bit stick the sharp end in drill reverse out the broke stud makes sence if not sceized

 

[Beels]

If there is anything sticking out, grab em with visegrips. If not use pick first then weld nut method, then drill/ez-out.

If you are lucky you will get it with one of the first 2 methods. Just remember to be careful with the ez-out. They are nearly impossible to drill if you break one.

Good points. The welding a nut on the exposed stud works well. The heat from the welding will expand the cast cylinder faster than the stud and if you get on it quick with a wrench, it should back out.

As for not breaking EZ-outs, I hear ya. I've had mechanics in out shop do that and it can quickly turn into a nightmare...

 

[Weekday Warrior]

it's prolly seized

if they are broken flush and seized don't mess with it in the sled, take the jugs out of the sled so you can get em on a work bench and do it proper



if they are seized good and tight just take it to a machine shop unless your well equipped (tools and knowledge) since you posted this I assume your not. Do yourself a favor and find a good friend or machine shop or both!

 

[Rixster]

Get some left handed drill bits. With a little luck the drill bit will bite and back the bolts right out.

 

[Beels]

Get some left handed drill bits. With a little luck the drill bit will bite and back the bolts right out.

If they're seized, you'll just wreck the bit.

 

[Rixster]

If they're seized, you'll just wreck the bit.

Yeah, cause drilling steel is hard on drill bits!

 

[spring snow hero]

so here's the logic in devilrmk's order.

first try to twist with vice grips.....duh. next weld a nut on. if you fail you can still center punch it and drill/exrtract. if you drill before you weld a nut on and get off center or you can't extract....it's too late to weld a nut on.