Damn... broken exhaust stud..

[burnoutboy]

OK.. So I went to take the exhaust off my Ytm 200 to get the exhaust fixed... Then I broke off one of the exhaust studs... There is about 1 cm left of the bolt still sticking out, I gave it a bit of a heat up with a blowtorch and tried getting it out with some vicegrips but no luck. Could a engineer get the exhaust stud out and insert a helicoil while still leaving the motor in the frame??


Cheers.

[junkrider]

Soak it with liquid wrench or blast-away. Tap gently on it like a sissy trying to drive a finishing nail. Repeat this process many times. Don't hit it hard (it is in aluminum, after all).

If that doesn't work, keep soaking it, grab it with vicegrips and put pressure on it while tapping it with a hammer. I can usually bust the toughest studs out this way.

When you reassemble, use never-seize on the threads. This prevents the oxidization that locks your threads.

-junkrider

[troy]

don't do like i did with my ERN, the end results was replacing the head....I tryed the heating, the soaking it, in the last i had some one drill them out, but he made a big mess out of it when he broke a drill bit off in side the head and a bolt extractor off in side the head..i know what your going though, i wish you all the luck. keep us posted:)

[Dirtcrasher]

They are very tough to get out. Gotta drill them straight to have a chance. Heat didn't seem to help me much. I put a 6mm helicoil in mine and it works fine, but - I drilled to deep and penetrated through the head. Thankfully it doesn't leak and I flushed all the metal out numerous times. If you can afford the gaskets, tgear it down and do it in a milling machine so it can be indicated in correctly. You won't evn need a helicoil if done dead on... GOOD LUCK!!

[junkrider]

A buddy of mine broke one off in his chevelle for the waterpump. He bolted the pump back on, then used a piece of tubing as a sleve to guide the drill bit. Took forever, but its an option if you can make a jig out of metal to guide the drill bit.

Also, he used a special drill... not sure what kind, but it took a lot to drill through the broken screw extractor.

[burnoutboy]

Hey guys...

took it down to the local mechanic.. Said it's no biggie really , so fingers crossed..

[Eric250R]

Well, here's a trick that has worked for me in the past: if you have a skilled welder, just weld another bolt onto the piece sticking out, then just put a rachet on the bolt you welded on and screw them out as normal.

[burnoutboy]

Well bad luck guys... mechanic cracked the stud off flush with the head.
He sais he has a engine reconditioner comming to try and pluck the stud out... what's the chance of him being able to do it??

[troy]

Well bad luck guys... mechanic cracked the stud off flush with the head.
He sais he has a engine reconditioner comming to try and pluck the stud out... what's the chance of him being able to do it??


AHH YES phase two of what happend to me, i'm thinking lots of drilling come his way...But at lease if he screws up the head, he more then likly has to fix it

[troy]

You know whats funny now after i change the head to get the pipe to bolt on, is i can't keep the damn bolts in they keep backin out, but nothing a lock washer can't fix...LOL...from one extream to the next.

[crackshot]

Use a center punch and ping it dead center on the stud a few times.
Then drill it out using a LEFT HAND TWIST drill bit. Sometimes the bit will catch and the stud will back out.

[aquapunk]

do what crackshot said, the left hand threaded extractors, you drill into your broken stud, then twist in the extractor, its left threaded so the more you twist it right, it goes in and grabs the stud, then keep twisting the extractor until the stud comes out, easy money..... had to do it with the footpeg bolts that broke off in my frame

[burnoutboy]

Thanks guys... If he can't get it out then I will have a crack at it with the left hand drill.

Cheers.

[thefox]

I would just drill it out and Heli-coil it. Those studs get seized in there real tight and I have broke many extractors because of it. Trying to then drill out a hardened screw extractor while keeping the drill strait is near imposable. If it broke in the frame I would try and use an extractor but not for the exhaust stud.

[burnoutboy]

Good news guys..

Mechanic got the thing out and put some brand new studs in there.
http://i107.photobucket.com/albums/m319/conrod90/trike3-1.jpg
http://i107.photobucket.com/albums/m319/conrod90/trike12-1.jpg

Thanks for the help..

[junkrider]

Looks really good. Play the lottery now. ;)