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post #1 of 7 (permalink) Old 09-30-2008, 06:27 PM Thread Starter
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Rust on header bolts

Hey everyone,

The bolts holding the headers into the engine case are rusted beyond recognition. Once I get the nuts off, will i be able to replace the bolts? or are they welded in. Just thought i'd ask how serious this is before I dig in.

I also have rust on the brake rotors. If i polish them out with flitz could that effect my stopping power? is there a safe way to polish the rotors?

I can handle the rest of the rust. Working on boats you get good at polishing stuff.

Thanks for any tips though!
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post #2 of 7 (permalink) Old 09-30-2008, 07:21 PM
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Jbass,

the header bolts are threaded studs, not welded. Since aluminium (cylinder head ) expands more than steel (header studs) when hot it's easier to get them undone on a very warm engine. Wear gloves doing it- in most cases the nut will be rusted solid on the studs: this means nut and stud will screw out in one piece like a bolt. Penetrating oil helps but not that much on these babies....

Replace with new ones, obtainable at any decent hardware store or at your dealer-not that pricey. (M8 studs and nuts,metric, 13 mm socket). Applying copper grease on the new studs aids removal in the future. You could use stainless studs and bolts, but SS reacts in aluminium and can get REALLY stuck although copper grease helps (a brand like Molykote is OK).

As for the rotors- frequent use of the bike is best to keep'em shiny...

Thieu

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post #3 of 7 (permalink) Old 09-30-2008, 09:36 PM
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+1 on the copper loaded grease.

As for polishing the brake rotor - just ride! The light amount of rust won't reduce your braking power, and at the end of the ride the brake disc will be nice and shiny.

To keep it that way, I recommend riding every day!

Actually, I would like a pickle.
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post #4 of 7 (permalink) Old 09-30-2008, 11:15 PM Thread Starter
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sweet, once im back in cali ill get back to riding everyday and get those rotors polished up. I wish that worked for the rest of the bike too.
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post #5 of 7 (permalink) Old 10-01-2008, 06:07 PM
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grease your nuts

When I bought my new 07 speedmaster I noticed the header bolts and numerous other parts were rusty I had a hell of a job getting the dealer to replace them and had to get a legal letter sent in the end before they replaced all the defective parts they tried to fob me off with you are not looking after your bike and all that nonsense and this is the best one "because I live near the sea!!!" got it sorted in the end, soon as they were replaced I greased them well and keep them that way, it seems to be working.
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post #6 of 7 (permalink) Old 10-01-2008, 06:10 PM
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A tip on getting stuck header bolts off: If you put two nuts on the bolt, you can put a wrench on each nut and spin them tight against each other to loosen the bolt. This worked on my 77 Honda, but be careful you don't wrench too hard and break the bolt off at the engine.

Death or Glory
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post #7 of 7 (permalink) Old 10-01-2008, 08:17 PM
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I know it works like this- have done the job myself recently. Did'nt even have this steal it out of a manual.(I happened to "find" the drawing.Can't remember where.) One error in my text: the "double" nuts com off after the stud is in place...
A manual is indeed a must; The one from Haynes explains this stuff in detail.(No, it's not a Haynes drawing)

Thieu. :

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