How to extract broken header bolt?

[Narcoden]

Mmmmkay, so I take out the GS500 from hibernation today.  All seems well, unplug her from the battery tender fire her up.  She's happy!  Joy!

So I go for a quick ride and bring it back for a wash.

As I'm washing and checking everything over, I notice I only have 3 header bolts  :dunno:

Previous owner must have broken one.  Well, had about 1/4 inch of the bolt still sticking out after I take the flange off.  So, I PB Blaster'ed it and let it penetrate for a few hours.  Then I dremeled a slot in it to go at it with a huge screw driver.  That bombed and I striped my slot.

Next, I bought a bolt extractor and drilled a small hole straight into the center of the bolt.  Burnt out at least 6 drill bits, tried hammering in the extractor and turning it out.  Nothin'...  It's damn near impossible to get that sucka' out!  :x

What else can I try?  Or, what might a shop charge to get it out for me?

Help  

-Craig

[jiggersplat]

last resort, drill the entire bolt out and put in a helicoil.  be careful not to get metal shavings into the cylinder though.

dan

[Adam R]

Which bolt are you talking about?  I assume you mean one of the bolts that secures the exhaust to the cylinder head.  If this is the case, then if you do take it to a machine shop you're probably best off taking of the entire head.

But, if the bolt is sticking out, then can't you get a vice-grips on it?

[GRU]

the way we used to do it is to get a metal pipe that's a little thiner then the broken bolt...bend the pipe to a 90 degree angle and weld one end to the broken bolt...then just unscrew the broken bolt

[Blueknyt]

Garry Ganu The Great Space Coaster! damn thats been awhile