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  1. #1

    Default Snapped EXUP valve bolts off flush with header. Can't drill bolts out to re-tap.

    Recently I heard a rattle in my exhaust, so I decided to investigate by removing the exup valve and seeing what was in there. After doing some research later I found out that some FZ's after awhile will develop a rattle from the small bushing/washer located on the exup valve. Well through the process of removing the cover, I snapped two bolts holding the cover on flush with the exhaust. I used very little torque and they just decided to snap (again, heard this was common.) I thought well, drilling these out shouldn't be an issue, boy was I wrong. I can only drill out maybe a quarter of an inch and now I cant go any farther. I've gone through 4 bits to see if they were the problem and even tried a Dewalt Cobalt bit and still can't drill through that bad boy. If I could just get it a little farther to tap I would be good, but I've ran into a brick wall it seems like. Does anyone have any ideas how I can drill any farther into this bolt so I can get a heli-coil or something in there? I've completely ran out of ideas and patience.

  2. #2

    Default

    Shitty deal! I've got nothing useful to contribute but here's a free bump.

    Good luck!

  3. #3

    Default

    Since you have already drilled them it may be too late but I have welded nuts (or washers) to broken off bolts and let it cool. This works often. Sometimes I weld a bigger nut to the first one just to add heat.

  4. #4

    Default

    Only thing I can offer is try low rpm while drilling and keep lubricating the bit. High speed and no lube will just kill the bit faster.
    Take your time.
    2011 FZ1 SILVER / ARROW HEADER / GYTR SLIP-ON / 16T / CORBIN SEAT / CRG LEVERS / AIRBOX MOD / DNA FILTER / COPPER DAWG FLIES / EXUP ELIMINATOR / PCV + IGNITION MODULE / QUICK SHIFTER / GRP DAMPER / MAGICAL RACING SCREEN / FUEL LINE MOD / WASHER MOD / 1" BAR RISERS / GRAVES SLIDERS / IVANS ECU / IDIOT ON THE SEAT

  5. #5
    Senior Member delbert's Avatar
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    Default

    What size drill bit you using ? ,, start with a 1.5 mm or similar and work your way up in small increments , time consuming but the only way :-)
    Cheers Delbert

    Tell it like it is

  6. #6

    Default

    I started out with a small bit and slow speed, really seemed to get the job done. I got the drilling far enough and wide enough to insert a heli-coil. Tomorrow I'm going to clean out the crevice with a q-tip and apply a thin layer of JB Weld in there for the heli-coil to be inserted. Wish me luck!

  7. #7

    Default

    Good luck, good luck!

  8. #8

    Default

    I just replaced my whole header with a fleabay Unit for $60. Machinist wanted $100 to drill and tap the broken bits and I've done it before with poor results. Took 20 minutes to swap the header - simplicity and lack of hassle were worth it.

    Sent from my SM-G970U using Tapatalk

 

 

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