What to do with a broken exhaust stud

While taking the exhaust off, 2 of the studs broke off with most of the stud still left to grabb onto. But they dont want to turn with pliers and i dont want to brake them clean off to were i have to tap them out.

I've got the motor out of the bike sitting on a crate, so i have all the room i need to work on it, i just dont want to have to remove the head if i dont have to.

 

Streetmaster,

There's tons of advice here and there on the forums for removing seized bolts, nuts, studs, etc.

1.) Start by soaking with PB Blaster or Kroil to penetrate and loosen. Did you try that? This might take several applications and letting it sit for a while.

2.) Maybe applying some alternating heat, then cooldown, several times will help loosen it. The only issue here might be direct flame heat which you might want to avoid. I don't know how it might negatively impact the nearby chrome.

3.) There are various extractor tools available from Sears that basically drill a reverse thread into the stud or bolt and then allow you to back it out. But they work best after you've applied some penetrating fluid or oil.

 

he only thing i've tried as of yet is with pliers, because i've only had the exhaust off a short time before i had to quit. Just thought i'd throw it out there to see if some one had a quick fix for this problem.

Im only able to deal with the bike on the weekends, so i'll give somthing a try then.

 

If you have access to a welder, weld a nut onto the end of the stud. The heat will help loosen the threads.....and you'll have a nut to put a socket onto :wink:

 

I had the same problem.....but the stud in mine welded itself to the head.

It just would not budge. Since it was only one, I decided it was best to leave it as is.

 

You have the engine out so do yourself a HUGE favor and take it to a machine shop and have the studs professionally extracted.

Easy on your psyche

Easier on your wallet if you have to buy the tools which will likely result in failure in the long run. Cost would probably be less to have the work done to remove 2 studs than to buy the tools

Your bike will be ready for you to continue your repairs by the weekend instead of fighting to get the studs out. Which would likely result in failure anyway.

You are probably looking at $25-$50 to have them removed

Good luck!

Loren

 

Another last resort option is to cut off what's left of the bolt so the cut would be hidden by the exhaust flange, and weld a hardened steel stud to the remaining part of the bolt. This way you won't have to mess with it again. Just make sure you use anti-seize on all the exhaust fasteners from this point on.

Of course it's best to pull the engine and have the stud drilled out and re-tapped, but still...