Took one for the team today...

So... I came home from work, excited to throw my pods on to see how they look. (I'm in the beginning stages of a little cafe-ish build on my XJ650J) So I started stripping down the bike, and I obviously wanted to take out the airbox so I could see that nice, open "v". I know how precious they are for those who like stock bikes, so I wouldn't ever consider cutting it up. Off came the hoses and carbs, then I realized some or all of the boots needed to come off the heads to fit it out. Most importantly cylinder 4. Guess which was the ONLY intake boot whose bolts were NOT GONNA MOVE. Yup - 4. So I hit em with some Kroil, walked the dog, etc. Nothing. Well, I really wanted the box out TONIGHT, and even though I have no use for the airbox, I thought of all the words of wisdom that I've picked up from here, and felt that I owed it to y'all to save an airbox. So... I snapped the bolt heads off, so I could remove the cylinder 4 boot... and now we have a very nice airbox for someone in need. Good deed done for the day.

 

Save it you may end up needing it.

 

Thank you for thinking enough to save the airbox.
While I am sure your anxious to start your adventure down the path of nightmares known as pods. I strongly urge you slow down for a bit to handle the broken bolts correctly. Done correctly you will never worry about them again.
Fortunately it is an outside cylinder, and should not require engine removal. But just in case make sure you soak the exhaust nuts, and engine mounting bolts with kroil to start. Also soak those broken bolts several more times letting them sit for 6+ hours between soakings. Plan on using a good share of a can.

While waiting for the kroil to soak in and start working you can take a center punch and mark the center of the bolts in case you need to drill them out later. This will also start breaking the bond that is holding the bolts. After a couple days of soaking, and beating it is likely that the broken bolts will come out easily.

During that time period you can take the other bolts you removed to the local hardware store and get some good replacement bolts. Throw the old bolts into the scrap bin.

~Ghost

 

Alum dissolved in warm water; eats steel but not aluminum.

 

Thanks for the tips gents! I'm not to worried about the bolts. I drilled out two exhaust manifold studs about a month ago without any trouble. Honestly, I found it very relaxing in comparison to my day job. I've really fallen in love with working on bikes. And agreed, Ghost. Pretty good angle for drilling on cyl 4. Slow and steady. Patience. Patience. Patience. Never do that stuff when anxious or tired. I'm a auto mechanic during the day hours, so I've been down similar roads before. I'll be taking the engine out at some point anyway to get the frame powder coated. Plan on going through the whole bike.

Haha! I know. I know. I've read the posts XJRider... I'm not trying to make a better running bike, or more performance. It's one hell of a well engineered machine. If it were in a bit better shape when I got it, I might have given it the full restore. (I'll save that for a 550. After poking around here and learning the ropes, I much prefer the look of them.) This one's just gonna be a little fun project. The pods are purely for aesthetics. Gonna strip it down and make a little cafe bike for buzzing around town and trying to look like James Dean. I appreciate the warnings though. I'll save it for someone in need.

Alas, I never did get to see the damn pods on there :/

Or try out my newly rebuilt starter.

And now I have a rack of carbs on my dining room table. Time for the Church of clean...

 

start those carbs in the dishwasher on "pots pans carbs" cycle