Looks like Suzuki has a problem over there with their bolts on these engines. Last year a buddy of mine broke both of them bolts when changing the exhaust(SV650 ‘05). Yesterday another buddy called me with exact the same problem.. (Gladius 650). I also think it’s kinda strange that Suzuki didn’t use a proper grade of steel for these bolts. They barely stick to any magnets and to be honest, these bolts are meant to break while they excessively heat and cool down a lot of times while riding.
Yea ive heard its a very common problem on sv650. I think it also might be the front cylinder thats more prone to issues, maybe because more exposure to water getting in there?🤔 either way, yea it sucks. Ideally, if I had to do it again if try to drill and tap it for the same size bolt as the oem one.
@@nickbuchananracing use a CNC machine to mill out the bolt and you can get out the excess by hand. After that use some kind of thread adapter so you can put on the exhaust and tighten it down with a nut instead of using a bolt. That way they come off more easily in the future.😁
1984 XL600r, single cylinder dual carb and dual exhaust XD. One of the exhaust stud internal threads finally went kaput. I was on the fence between a heli coil or time serts but the stepped stud method seems more robust. Looks like your repair has been holding, evident of your recent videos with the SV650?
Yea it seems to have held up well. Hasnt come loose since. And this bike is a track only race bike so its only ridden hard at high rpm all day. Done at least 1000 miles ( at least 20hrs of run time) of track riding since.
@@nickbuchananracing Good to know it's held up well! I guess we'll find out how well it will work in a thumper. One minor difference is the OEM stud cinches against the mouth of the hole and not at the bottom of the hole. I'll either use a bottoming tap to create a shoulder for the stud tighten against or drop in a spacer to bottom out against. Fingers crossed!
Hey, hope you're still responding to comments. On my bike, one of the bolts is broken and I can't take it out for the life of me. I replaced the exhaust and tightened it with only one bolt and some exhaust paste. Will this be a problem? If so, a big one? Im a student and dont have the tools or budget to get them, or to go to a shop to fix it, unless I REALLY have to. Thanks!
It is a problem if it leaks. Feel around the flange and see if you can feel any exhaust pressure escaping. If its leaking you need it fixed. Also how many cylinders is the engine. If its a 4 cylinder, the other cylinders at least help hold the whole manifold in place. If its a single id be a little worried it could shake loose
Nick I've got the same problem in my Sv650.But slightly worse.I was trying to drill out the leftover broken bolts on the bike and it didn't go too well.One is still fine and it's like sticking out 5 mm but the other I messed up that hole a bit.And I'm thinking the only way to fix it is to get them out and weld some aluminum to make the socket look new again.My question is .Can I just take the cover off the bike like you did and assemble it afterwards without doing anything to the engine? Is it just like plug and play?Or do you have to do some extra work?
If your gonna have it tig welded im pretty sure you have to remove the cylinder like I did. To do that, you would need to remove the entire engine. If your cylinder is completely screwed, my friend has a shop that sells secondhand SV parts for good prices. Mad8v.com
Looks like Suzuki has a problem over there with their bolts on these engines. Last year a buddy of mine broke both of them bolts when changing the exhaust(SV650 ‘05). Yesterday another buddy called me with exact the same problem.. (Gladius 650).
I also think it’s kinda strange that Suzuki didn’t use a proper grade of steel for these bolts. They barely stick to any magnets and to be honest, these bolts are meant to break while they excessively heat and cool down a lot of times while riding.
Yea ive heard its a very common problem on sv650. I think it also might be the front cylinder thats more prone to issues, maybe because more exposure to water getting in there?🤔 either way, yea it sucks. Ideally, if I had to do it again if try to drill and tap it for the same size bolt as the oem one.
@@nickbuchananracing use a CNC machine to mill out the bolt and you can get out the excess by hand. After that use some kind of thread adapter so you can put on the exhaust and tighten it down with a nut instead of using a bolt. That way they come off more easily in the future.😁
1984 XL600r, single cylinder dual carb and dual exhaust XD. One of the exhaust stud internal threads finally went kaput. I was on the fence between a heli coil or time serts but the stepped stud method seems more robust. Looks like your repair has been holding, evident of your recent videos with the SV650?
Yea it seems to have held up well. Hasnt come loose since. And this bike is a track only race bike so its only ridden hard at high rpm all day. Done at least 1000 miles ( at least 20hrs of run time) of track riding since.
@@nickbuchananracing Good to know it's held up well! I guess we'll find out how well it will work in a thumper. One minor difference is the OEM stud cinches against the mouth of the hole and not at the bottom of the hole. I'll either use a bottoming tap to create a shoulder for the stud tighten against or drop in a spacer to bottom out against. Fingers crossed!
Hey, hope you're still responding to comments.
On my bike, one of the bolts is broken and I can't take it out for the life of me.
I replaced the exhaust and tightened it with only one bolt and some exhaust paste.
Will this be a problem? If so, a big one?
Im a student and dont have the tools or budget to get them, or to go to a shop to fix it, unless I REALLY have to. Thanks!
It is a problem if it leaks. Feel around the flange and see if you can feel any exhaust pressure escaping. If its leaking you need it fixed. Also how many cylinders is the engine. If its a 4 cylinder, the other cylinders at least help hold the whole manifold in place. If its a single id be a little worried it could shake loose
Nick I've got the same problem in my Sv650.But slightly worse.I was trying to drill out the leftover broken bolts on the bike and it didn't go too well.One is still fine and it's like sticking out 5 mm but the other I messed up that hole a bit.And I'm thinking the only way to fix it is to get them out and weld some aluminum to make the socket look new again.My question is .Can I just take the cover off the bike like you did and assemble it afterwards without doing anything to the engine? Is it just like plug and play?Or do you have to do some extra work?
If your gonna have it tig welded im pretty sure you have to remove the cylinder like I did. To do that, you would need to remove the entire engine. If your cylinder is completely screwed, my friend has a shop that sells secondhand SV parts for good prices. Mad8v.com
What exhaust stud did you use? What lenghts? Where can I get one?
@@tamma369 i dont remember sorry, think maybe I got them from Ace Hardware, my local hardware store
@@nickbuchananracing be grateful for your Hardware store, that they have such parts available.
Snap both front bolt today doing a swap
Were you able to get it out without drilling?
Broke my final two exhaust manifold bolts on my 1983 Suzuki GS850GL
I have the same problem 2001 Suzuki v650
May the odds be in your favour
Had the same happen to me, have to deal with it now, 4 weeks prior had the front spark plug snap, don't do that, expensive.
Today GSF650 bandit.