Back in the spring I was doing the servicing where you loosen and retorque the head bolts and the exhaust bolts.  Anyway, when I did the exhaust bolts two came out ok, and two brought a fair amount what appeared to be thread with them.  I was able to get them back in, but I know they need to be rethreaded and the bolts replaced.  What are you all's thought's on how to go about doing this?
The way I see it I have a couple of options.

• Leave it be and never plan on pulling the exhaust
• Drill it and helicoil in place
• Pull the head and drill it myself with a drill press if I can find one
• Pull the head and take it to a machinist

BaltimoreGS did it in place on one of his bikes, but said they didn't come out straight.  I expect I'd run into a similar problem with a hand drill at a weird angle.  That had me leaning towards pulling the head, but looking at some other threads that seems like it will be a mess. 
If I take it to a machine shop, I could get a valve job done since everything is out which is tempting, but probably not really a big deal on the GS. 
If I pulled the head and took it to a shop would I need to pull the cams and all that jazz off?

Can I pull the head with the engine in the frame?  Is it a huge deal?  I know I'd probably need new a new head gasket, anything else?
Anybody know any machine shops in MD that do MC head work?

Thanks.   

If you were able to get the bolts out in one piece, the hole should still be reasonably straight.  A helicoil would be pretty easy in that case.  Heck if the bolt is a M8x1.25 I'll send you the installation tool, tap, drill bit, and a couple helicoils.  Just send them back when you're done.

What bolts are they.  Can you remove the removable part of the frame to gain space.  I'd definitely try that route before pulling the head.  I just did this same repair on my SV last month and it took all of 10 minutes.  

I think the ones that were problematic were the inner two bolts, but it's been a while.

I can pull the frame section.  Does that require anything special like bracing the engine?  It's a pretty big chunk of frame.

Thanks on the helicoil offer.  I don't know what bolt size it is yet, or what sizes I have lying around though.

Tap it to a slightly larger SAE size.
Then make sure you put different looking bolts on them, co you dont get confused and put the stock GS bolts on the thing.
Cool.
Buddha.

Quote from: The Buddha on November 29, 2009, 01:45:42 PM
Tap it to a slightly larger SAE size.
Then make sure you put different looking bolts on them, co you dont get confused and put the stock GS bolts on the thing.
Cool.
Buddha.

Why would going to the next size up SAE be beneficial?  I remember seeing you suggest that in a related thread.  I get why you'd use different bolts to differentiate SAE and Metric, but why SAE at all?

I haven't thought this far ahead yet, but I might go ahead and do studs like people have suggested for people who have to drill exhaust bolts out.

Thanks. 

Quote from: PachmanP on November 29, 2009, 11:28:44 AM


I can pull the frame section.  Does that require anything special like bracing the engine?  It's a pretty big chunk of frame.

Probably nothing special.  Put the bike on the centerstand, or better yet some dedicated race stands.  Put a jack under the engine.  You should be good to go.  

Here's how I see it, and someone correct me if I'm wrong.  You'd be removing 2 of the 3 motor mount bolts (if I remember right...my GS is spread throughout the nation).  The engine won't go anywhere with a jack under it.  If you leave the back motor mount bolt in, you might be able to use it as a pivot.  That way you can move the entire front of the engine up or down for more room.  

Anyway, if it was me...I'd do whatever it takes to not pull the head off.  That's way too much work for what you're trying to accomplish.

Hey Danny,

Don't let my sloppy work on the helicoiled Honda discourage you, even in the best of working conditions I'm hard pressed to hold a drill at a proper 90 degree angle     In hind sight I should have taken 10 minutes and removed the front forks to make that head more accessible.  The studs may be a bit crooked and look like s**t but they have held the exhaust tight for a lot of miles since   

I believe Buddha is suggesting that instead of helicoiling to the original size that it would be easier just to get hold of a SAE tap that is slightly larger than the metric bolt and tap the holes (no drilling required).

-Jessie

Yea minimal drilling and you're real need is to get threads in to hold it. The next one up in metric will be too big.
SAE is like 1/2 size, 8mm is the stock if I recall. next up in metric is 10mm. I dunno, maybe a 9/32's could be better if you can find it. If you heli coil it it will have to be drilled and tapped in that tiny nook you got in there.
BTW I did mine without the forks in and it worked OK many years ago. I consider it the hardest job I have ever dont though on a GS to date.
Cool.
Buddha.

Thanks guys. 

SAE makes sense now.  I think I'm going to go ahead and give it a shot in the bike.  Drop the forks (they need an oil change anyway) and see if the frame section needs to come out.

Now I just need to make some time...

Quote from: The Buddha on November 30, 2009, 07:25:59 AM
BTW I did mine without the forks in and it worked OK many years ago. I consider it the hardest job I have ever dont though on a GS to date.
Cool.
Buddha.

That's encouraging...

PachmanP

You think some threads came out with the bolts the last time you tightened them.  Is it possible that only a tiny bit of thread came out and the rest are fine and you don't need to timesert / helicoil?  Is it possible that it was not thread at all that came out, but a burned slice of the old gasket, or some burned anti seize on the threads?

AND:  Right now the exhaust is not leaking?  I'm all for unnecessary surgery in the name of science.  When I pull shaZam! apart unnecessarily I sometimes end up breaking three more things in the process.  If it is just for fun, can't fault you for that at all.

BeerGarage

If you do helicoil or especially if you do timesert, post up some pics, please.

Quote from: BeerGarage on November 30, 2009, 09:28:14 PM
PachmanP

You think some threads came out with the bolts the last time you tightened them.  Is it possible that only a tiny bit of thread came out and the rest are fine and you don't need to timesert / helicoil?  Is it possible that it was not thread at all that came out, but a burned slice of the old gasket, or some burned anti seize on the threads?

AND:  Right now the exhaust is not leaking?  I'm all for unnecessary surgery in the name of science.  When I pull oh my goodness apart unnecessarily I sometimes end up breaking three more things in the process.  If it is just for fun, can't fault you for that at all.

BeerGarage

Yeah it was shiny Al bonded to the bolt threads when it came out. 

And yeah I could leave it be, but it'd be a pain if it ever did need to come out and I need something to do beside troll the forum all winter...

I'll see what I can do for pics, too.