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Sheared exhaust stud, help.

  • Thread starter Thread starter gtemplarbond
  • Start date Start date
Just removed mine tonight !

Just removed mine tonight !

Soaked with PB Blaster for a couple of minutes !!! Yes minutes and thought I would give them a try.

All 8 came right out, with no issues !! I was actually kinda worried about taking them out thinking since the bikes been out in weather (NEW ENGLAND Weather) for ?? how many years. Found a hole in the 4in1 header I need to weld before tunning her up. Sorry to say my header removal was a no headache job this time...
 
Had this happen on one of mine. Mine was so bad, it looked like it had actually "welded" itself in there. I cut it off as close to the edge as I could; filed it down as flat as I could; center punched it best I could; drilled it out with a 6mm bit instead of the 8mm it originally had; so I really ended up threading what was left of the original bolt stud that wouldn't come out. I liked that better than the idea of me getting into the aluminum if I got off a bit with an 8mm bit. I used a 6mm bolt and it's worked fine for me. Where you start your hole is what's going to make or break this deal though.

Before:
headerbolt.jpg


After:
DSC_07682.jpg
 
IIRC these are not blind holes so you MIGHT be able to get penetrating oil behind it from the other side of the head. The bolt faces down so oils tend to run away from the front side of the problem.

Mine have never been off, this year it's going to happen and I will replace them with studs and nuts. The bolts were a bad idea.

I'm going to try warming the engine up first and with the bolts hot give it a hit. I use an impact screwdriver that has a socket attachment. Just like removing stuck screws it seems to work good removing the bolts. The last one I took apart was a 750L head that sat for a few years. I really had to work four of them but they all came out.
 
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