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What to do with broken exhaust manifold studs?

  • Thread starter Thread starter jfman
  • Start date Start date
J

jfman

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Both times I took apart my GS400E parts bikes, one the the manifold studs broke clean off the head.

Whats a good trick to prevent this and how to fix it if it happens.

Welding a lever on it any good?

Apply heat?
 
Last edited:
Intake or exhaust header? If there is enough sticking out I like to weld a nut on it and try it again. The welding heat will help break the corrosion too.

I take a nut thats big enough to go over the remaining stud and start welding on the stud and swirl my way outward till the nut is welded on good. Then a GOOD blast of penetrating oil ( its gonna smoke like crazy).

Then gently rock back and forth and see if it works itself looser and looser.
I also have a set of Craftsman stud extractors that will sometimes get a good bite on the studs.
 
Haha, you a funny guy Steve :p


I use anti-seize and haven't had a problem extracting exhaust studs yet. Even with stainless alen bolts!!

Chuck's way works.

Weld a nut on then hit the back with lube or beeswax. It will suck the stuff right in.

then just work it back and forth until it comes out.

If you don't want to weld it drilling works as well but you have to start small and only go in a certain depth.

Measure what that depth is and put tape on your drill bit so you know when to stop.

Do not use easy out. Your just asking for more trouble.
Drill small. and work bigger until your nearly at the size or the original bolt.

Then maybe you can pick the rest out of the threads or use a reverse drill bit. Or use the easy outs at this point but not before.

I just had to do 4 of these on my gs500 spare head.

Try and keep the drill as centered as possible and go with slow speed and lots of lube.
 
So dont weld a tool to it but just weld a nut on there... hmmmm...


So I weld inside the hollow part of the nut... onto the remaining part of the stud.
 
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