XBR front head bolt rusted

[richardeblack]

Hello All
Trying to get the head off my new XBR to sort out the broken exhaust studs and apart from one of the 8mm bolts breaking which I can just add to the exhaust ones needing sorting I have run into a real problem.  The front bolt, just in front of the spark plug, has rusted so badly that it has gone from a 12mm head to being able to hammer on a 10mm socket.  Unfortunately I can't get it on far enough to be able to release the bold.  I obviously have some options if I remove the engine (drilling the head etc) but really want to leave it in.  i have thought of welding on a box spanner if I can get it clean enough but only have a mig welder and have found, on attempts to remove the rusted exhaust studs,  that the box will probably break off just above the weld.
Has anyone had the same problem (the bolt is in an incredibly vulnerable position from road salt etc) and what did they do about it please?
Thanks and have a great New Year.
Richard

[timbo]

They are famous for this unfortuneatly. Not sure which option to go for Richard, but I'm sure someone on here will know. Plus try a 'search' on the site, as its bound to have come up on here before. I reckon weld  a socket on from the top, ie, fill the centre of the socket, leaving room for the wrench obviously. Though, I guess it will prob snap the stud   

[richardeblack]

Thanks for that.
I will probably try the welding route but am not sure how to clean it. Could gritblast it but not sure how to keep the grit out of important bits. Going to buy a dremel tomorrow to have a final go.
Interestingly my earlier higher mileage engine has no sign of corrosion and the bolt would be easy to get off if I wanted to. Different design.
I'll let you know how I get on.
Thanks
Richard

[SteveC#222]

The bolt head on mine is also very corroded - luckily I've not had need to remove it but I think it would cause some headaches if I ever had to .  Must be an XBR thing.

[mthee]

Thanks for the heads-up, I'll be careful to keep mine in good order.

[timbo]

Can't remember, are they a domed nut? If not, I'd replace with one.

[richardeblack]

Hello there
It is a bolt but the one on the one I am working on seems to have a large integral washer unless it has just corroded into itself.
Not sure what to replace it with but will have a look at my working one with a view to ensuring, if poss, that it is ok.
Off to get a dremel to try and do something with it.
If not it is engine out and it can be properly cleaned and will go into y very nice powder coated frame and I will build a tidy one.
Cheers
Richard

[welland99]

Hello All
Trying to get the head off my new XBR to sort out the broken exhaust studs and apart from one of the 8mm bolts breaking which I can just add to the exhaust ones needing sorting I have run into a real problem.  The front bolt, just in front of the spark plug, has rusted so badly that it has gone from a 12mm head to being able to hammer on a 10mm socket.  Unfortunately I can't get it on far enough to be able to release the bold.  I obviously have some options if I remove the engine (drilling the head etc) but really want to leave it in.  i have thought of welding on a box spanner if I can get it clean enough but only have a mig welder and have found, on attempts to remove the rusted exhaust studs,  that the box will probably break off just above the weld.
Has anyone had the same problem (the bolt is in an incredibly vulnerable position from road salt etc) and what did they do about it please?
Thanks and have a great New Year.
Richard

Good luck.  Any chance of some photos:  before, during and after?

[iansoady]

My parts book for the SLR seems to suggest that it is a 6mm x 35mm flange bolt. I understand that one of the problems with these is that the bottom end of the thread (which is exposed) corrodes so it won't unscrew.

Unless you're lucky does sound like an engine out job.

[themoudie]

Lashings of copper grease when the new one goes in!
Best of luck wi' it,
My regards, Bill

[JOOLZ]

Well worth replacing that bolt with a stainless steel item

[onthecheap]

When taking the head off my XBR the front bolt was suffering the same symptoms but gave up without a fight. It got me to remember I had this problem many years ago on a bike a cant or don't want to remember ! My solution at the time was to make the washer with a couple of tabs welded to it to form a V in front of the nut and then I covered the bold head in silicone. A bit of work yes but next time I took the head off it was a piece of pee.
I would personally go down the stainless bolt route due to the dissimilar metal problem. Steel bolts with copper grease on clean threads should be fine but adding a stainless bolt to the mix could be a step too far for a variety of reasons.