Sheared off exhaust post

Unfortunately I just noticed when taking off my exhaust that one of the posts has broken off inside the engine. I have used an easy out to get most of the stripped bolts/screws out throughout the bike, but I am a little afraid of damaging the aluminum. Any other suggestions on how to remove the post? I have tried searching the forums, but there is just so much information on here (which will end up being a god send at 3 in the morning when I have no clue where to go). Thanks for the help, from everything I have read on here I have found my second home!

 

Get some good penetrating oil P B blaster or KROIL oil and spray it a few times before you start if you can then hit it with a hair dryer heat it up and spray it over and over center punch the broken stud and drill it with the right bit for your easyout I would use a new one if possible. If you are real uncomfortable take it to a shop. drill on the slow side and use oil on the bit if you decide to go for it I like to use a tiny bit and then step up that way if i start to get off center i can correct it before I do any damage. You can always heli coil it if you mess up the threads

 

Thanks, I will try that today. I wasn't sure if I could helicoil in the event of a mistake

 

Buy a set of reverse drill bits and build one of these http://spaco.org/Blacksmithing/TapDrillBlock.htm
to use with the bits. It will help keep you perpendicular to the head and keep you from binding.

 

Try heating the area around the broken stud with a small propane torch,( it will only take a small amount of heat) and melt some candle wax into the threads. Let the area cool and then back the broken stud out with your easy-out....works every time.

 

if you can, just cut a small slit in it with a dremel and use a small flat head screwdriver to back it out.

 

The single biggest favor you can do for yourself is to take the bike with you when you introduce yourself to the dude at the machine shop! They will extract it for you and you won't have to lose any sleep worrying about what you are going to do now that the threads in the head are all buggered.

Loren

 

Or you could dissolve it: http://www.chemical-supermarket.com/pro ... ductid=574

 

I use left handed drill bits. good soak in penetrating oil. And start small. it relieves the pressure as the center hollows out. then put in a bigger bit and low and behold the come spinning out when the next bigger bit catches a good bite. I have had to go to a bigger yet bit a few times but very rare an usually larger bolts.

If your scared of it though, I recommend a shop. They wont charge much to do it.

A bad drill cut means re taping to the next size and drilling the mating hole bigger. or drilling bigger yet and inserting a helicoil.