I broke two of my exhaust bolts and came across this site that had good info on broken bolt removal.
I havent been successful on removing mines yet, but found out that it may take up to a week before WD-40 can
penatrate the rust. Not in a big rush to ride the bike yet. Still got to get other stuff done first.

heres the link, could come in handy someday.

http://www.asashop.org/autoinc/may2003/techtotech.cfm

 

I found some little jewels at Lowe's when I broke a rotor bolt (Honda's fault [:@]) -- they're called Grabit. I was skeptical but the bastard pulled the bolt right out.

 

how does it work?
just curious, cause I'm just spraying it with WD-40 and leave it alone for the weekend
cause I'm going home. If it doesnt work them I might try that thing you mentioned.

 

They're similar to an EZ-Out. It's basically a hex bit that fits in your drill. One side has a left hand drill and the other an extractor (also left hand). I just took a small punch and made a mark in the center -- drill with the drill side, swap it around and extract.

 

Hey you might wanna try some stuff called "PB Blaster". It runs circles around WD-40. I have never had much luck with WD-40 on rusty bolts. I use it on header bolts and flange bolts for cars, it works great. Good luck.

 

Ya, we use PB Blaster at work and it is great stuff!! Only thing is I've never seen it in stores -- guess ya could google it to find retailers. It does stink really bad though -- if ya get it on your hands you'll smell like pb blaster the rest of the day[:'(]

 

yeah, just got back from visiting family in Ca. over the 4th
when I got back, I was not as motivated to fix my bike...
but a friend said he would help me load my bike onto the back of his truck so
I could bring it to the hobbie shop and use their torch.
Oh yeah, thats the approach i am using - torching the tips of the bolt, then quenching them
with water to shock them and to break the rust.
In theory it would work, I'll give a try and see.
should have results tommorrow.

 

Uh, is that on a 93 CBR? Don't know if that model had any aluminum bits but you definitely want to be sure before sticking an acetylene torch to it.

When ya do put it back together remember neverseize is your friend

 

yeah I have a 93 CBR and the bolts look as tho they are metal and not aluminum.
The head looks as thought it is, but I plan to heat the tips only and not even to the point of
cherry red, may be just 20 sec on and quench, tap with a hammer, then double nut the bolt.
I'll let yah know what works the best.

 

Sounds like ya got a plan -- I'm just overly cautious with aluminum and fire. Aluminum doesn't melt for me -- it just goes away. Where? Who knows. But it's a pain in the *** to replace it. Good luck with the extraction.