Tips on how to remove a broken exhaust stud?

two-smoker

I reject your reality, and substitute my own!
I had some issues with the exhaust on my TX500, and had to remove it completely to get it separated out... Problem is, one of the exhaust studs snapped about 1/2" from the head. Normally I'd just grab it with a vise grip and twist, but I absolutely want to be sure I don't cause any more damage than I have already. I've thought of cutting a notch and using my impact driver, heating it up and using a special stud tool (which I don't have), etc. When I tried double-nutting it and turning it out it snapped at the base of the threads, leaving just 3/8" of stud. Ideas?
 
Hmmmmm. If heating it up and cooling it down doesn't break it loose, you could try drilling down the center of the stud. You have to nail that hole perfectly though. And keep an eye on ebay just in case.

Hopefully somebody else has a better idea though.
 
Put an oversized nut over the stud and weld the nut to it (welding from inside the nut).


The welding heats up / loosens the stud, and the nut gives you something to turn it out with ;)
 
hillsy said:
Put an oversized nut over the stud and weld the nut to it (welding from inside the nut).




The welding heats up / loosens the stud, and the nut gives you something to turn it out with ;)


+1

.
 
It's become fact for me that not all "fix-it" plans work when it comes to broken bolts. Most people swear by welding a nut on, others soak the bolts in PB blaster or something similar for days before taking an impact gun and zipping them out, that usually works. Welding a nut will work in most situations, but not all. Our GS550E had two broken exhaust stud bolts, and welding the nut only made it worse. Any time I tried welding a threaded nut on, letting it cool, heating it up, and wrenching it out, would only snap off additional threads and the nut on the bolts, each time leaving less and less space to use that method.


The easiest fix? We spent like $50 on a decent/pretty nice and complete tap and die set. We simply drilled out the two bolts, and re-tapped the head. This fixed our issue in an hour, and the exhaust and everything was back together and on the bike. As the others mentioned though, just make damn sure that you're in the center of the bolt when you start drilling, because if you end up tapping the bolt to the left or right of the left-over broken stud, and not in the center, even an 1/8" is enough to cause the collars to not meet up and bolt up crooked or stressed.


P.S. I'm not saying extractors don't work, but Any time i've used an extraction kit on a bolt like an exhaust stud that's broken, they never worked for me. They would thread in and twist so much, that I was worried it was going to break the extractor in the bolt, which makes the issue twice as hard now to fix if that happens.
 
Still working on it. My buddy bought a set of studs extractors, but the 8mm, which is the one I need, is missing. Just waiting for the tool guy to cough one up. Three bike got pinned into a corner, so I've not been able to get to it to do any work, besides.
 
I had this same problem on my xs750.. For me, a routine of heating it up, spraying it with pb blaster, and tapping it with a rubber mallet over the course of a few days was all it needed for me to be able to slowly work it out with a good set of vice grips. My $0.02, get some pb blaster and have some patience, go for the easiest solutions first! It just might work.
 
I won't need to use an easy out unless the stud breaks off flush with the head. I've got a half inch or so sticking out yet, so I've at least got something to grab onto with a stud remover. I've been soaking it in penetrant, so we'll just have to see what happens.
 
honest to god, the weld nut is the easiest method... as said, heat loosens it up quickly, and with a spanner the stud comes out quick and easy.
 
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