I picked up a bike and the head bolts are pretty rusted. Have you guys ever replaced your bolts? Is it tricky or can I simply pull them and clean them or just replace them?

Thoughts?

 

You didn't tell how old the bike is. I would replace them if the bike is too old. Cheap enough to replace them instead of going thru the hassle of cleaning them.

 

It is a 1996 sportster. In great condition the bolts are just rusted. It starts and drives great too. Just a cosmetic issue.

 

Lot's of bikes have this surface rust on the head bolts. I just used chrome covers to make it look better.

 

Don't go to the effort of pulling the heads over rusted head bolts. The new ones will rust shortly anyways. Leave it alone.

 

Here is a picture. It has covers but they need cleaned up. I also have to get some spark plugs, they look a little rough.

 

Almost every sportster I've seen has rusty head bolts. I wouldn't worry about it. Get the "chrome" covers if it bothers you that much.

I'd only replace them if I were doing an engine tear down where the bolts are getting removed.

If you try to remove them without the proper installation torque sequence you could be opening up a whole other can of worms. A can of worms so bad that rusted head bolts don't seem too bad.

 

You can't replace those bolts without also removing the ones you can't see, to get the torque sequence correct, so wear your rusty head bolts with pride - like the rest of us! Just replace the spark plugs with new ones, if you wish.

 

Aha. Just the situation I have with rust on headbolts. XL883C 2005
You confirmed my suspicion; loosening them would let loose a nightmare with everything they are holding tightly together! Thanks for the photo, Bearjew.
I'm happy riding with surface rust on the bolts but I am selling one of the two bikes and a prospective buyer will see rust as lack of care generally.
I'm going to try a Dremel tool with teeny brass wire brush & I'll post my results with before & after photos.

(I thought of naval jelly and other rust-removing liquids carefully painted on but it could stain other areas even with lots of hosed water rinse.)

 

clean up what you can. beware the razor blade contrast fins.