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Broken Bolts from hell!

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Jim P.

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:rofl: I have 3 broken bolts in my exhaust manifold. I believe from vibration and wear. I then went ahead and snapped the bolt that goes from the curved tune pipe into the exhaust manifold. How hard is it to remove the manifold? I am ordering a used exhaust maniold and plan on having it replaced professionally before I make it any worse. I probably should have heated the bolt up but was concerned about blowing myself up with whatever little gas is left in tank. Thanks Jim
 
hahaha . ebay buddy ! if i break one bolt off in a manifold on these things i will get them off ebay all day long . the most common reason for breaking is a bolt missing from a rubber mount on the pipe some where . if your on a sportster then you can do this your self with no problem . the bolts holding the manifold in place are i think a 10mm shaft and you will need a 8mm allen with a 3/8 long handle ratchet . and assume they have some corrosion built up on them but they are big enough to take some pulling tourqe and should not break at all . i really hate to see you get raked over the coals for this simple job , and you should have gobbs of room in the speedster . dont worry about the fuel tank , it sealed pretty good , i would how ever open all hatches and coolers and air it out for a bit but i use my map gas torch all the time inside skis and some have a gasy smell but if your skis is open to the air then the risk is minimal at that . if you do take it to a dealer it should , in my opinion be no more than a 100.00 dollar job to replace the manifold . it easy dude . if your new used manifold has any signs of corrosion in the bolt holes then find your self a drill bit the same size may be a hair bigger and run thru the holes to clean the out and be sure to use anti seize on your bolts and be sure you have all your mount bolts in too or it will break again
 
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