broken manafold bolt

zeolig · Post by **zeolig** » Fri Oct 17, 2008 7:33 am

I need some advice again. Short of welding the manafold is there a way of stopping a leak between the manafold and the muffler. When I picked up the Spree the back tire was flat and off. I noticed when I removed the muffler to reinstall the tire one of the manafold bolts were broken off. I tightened up the one bolt but there is a leak. It looked flush but it was still leaking Not to loud but loud enough. I do not want an exhaust leak to lean out the engine and cause any damage. Anyone aware of a quick fix such as a gasket or muffler cement as a glue between the pipe and the manafold? I tried putting a bollt through the broken hole with lock washers but it kept slipping out. Any ideas would be greatly appreciated. zeolig

keithw · Post by **keithw** » Fri Oct 17, 2008 8:39 am

The manifold stud is screwed into the cylinder. The broken one will be a bugger to remove but once you get it out you just screw a new one in. I would not even try to repair it with the cylinder on the bike. This would be a good chance to check to see if you have a dished piston and replace it with a domed one, port the exhaust, and mill the head.

Another option would be to go to your local auto parts store and pick up some exhaust gasket material. Cut a gasket and install between the pipe and the port. Is the copper ring missing from yours? It goes between the pipe and the port. If missing it doesn't seal very well.

keithw

zeolig · Post by **zeolig** » Fri Oct 17, 2008 9:39 am

I'm not sure if the sleeve is missing. I'm in work but I will check when I get home. I will try the automotive store suggestion because the bike runs great and I would like to go for the quick fix at least until winter sets in. Maybe during the winter months I can back the bolt out of the block. Would I use heat or mystery oil or something like that when I try to remove it?
Thanks zeolig

Diesel Spree · Post by **Diesel Spree** » Fri Oct 17, 2008 8:57 pm

if any of the bolt is sticking out take a torch and heat it up becareful not to melt it then take a vice grip and turn it out and u can get a new one from the dealer for .79 cents or u could drill it out and retap it and just put a bolt in there.

Kenny_McCormic · Post by **Kenny_McCormic** » Sat Oct 18, 2008 9:54 am

warm it up with a torch just hot to the touch
spray it with PB blaster
walk away
repeat a couple of times
heat again and try turning out with vice grips.

zeolig · Post by **zeolig** » Mon Oct 20, 2008 11:53 am

Thanks all. The injury to the manafold was a little more extensive than I thought. Part of the manafold was broken exposing the threads where the bolt used to be. I got a thick manafold gasket, cleaned the manafolf and muffler flange real well,slid it over the sleeve, which was still there and used some muffler cement. I tightened up the one bolt, no leak. I'm scooting quietly. zeolig When I first drove it the headlight was working great. Last time I started it I noticed no head light high or low beam. Is there a fuse for the light and if so where is It? If not is a headlight hard to change. Thanks again. zeolig

Post by **noiseguy** » Mon Oct 20, 2008 2:09 pm

For a more permanent repair if it give you problems later: You could push a new stud into the remains of the thread, and have a muffler shop spot weld the stud in place. Otherwise you can replace the jug to repair.

zeolig · Post by **zeolig** » Mon Oct 20, 2008 2:48 pm

Thanks! Sounds like a winter project. zeolig