Busted an exhaust stud

[foxjohnc]

Well, I removed my pipes and one of the exhaust studs snapped off. Looks like there is enough clearance to drill it and remove it but am not sure. What is the correct procedure in doing so? I am not very comfortable doing this myself and I dont want to remove the engine. Would a yamaha dealer be able to do this? The other stud is holding for now and I put locktite around the nut so it will stay in. When it snaps off I am screwed.

[ratbyk]

Broken Stud

First step is to put a center punch mark right dab in the middle of the broken section. If the broken portion is ragged file or grind it flat enough to ensure you are able to mark it dead center. Next drill a small (1/8") pilot hole well up into the stud. At this point you have two choices, continue drilling larger and larger holes until you can run a tap up inside to clean up the threads or get an easy-out and try and back the broken stud out. I have found on exhaust studs that because of their composition and having been extremely hot and cold so many times in their life that they have become very hard and brittle., All to often in this case the easy-out breaks off in the hole and you then in even deeper do-do than before.
Try drilling it out but you must start in the very center or you will be drilling alloy head on one side at the end.
Ken/Sooke
78E Ratbyk
82 FT500 "lilRat"

[Geezer]

If you have access to a wire feed welder, hold an 8mm nut over the broken off stud and weld it to the stud. After it cools, you can screw it out with your fingers.

All the usual warnings about fire safety apply...

Geezer

[foxjohnc]

The other one busted off today. What sucks is the fact that both are busted about 1/4 of an inch inside of the head. Welding isnt an option. So it looks like the center punch and drill is the only option. What kind of bits should I get? Anyone happen to know how deep into the head the stud goes? I dont want to drill into the head.

[ratbyk]

Broken Stud

Any metaL HS drill bit will do, as long as it is sharp. So far as depth goes, as soon as you pass through the steel stud you will feel the drill start to work much easier,STOP!
Ken/Sooke

[Geezer]

Originally posted by foxjohnc
The other one busted off today. What sucks is the fact that both are busted about 1/4 of an inch inside of the head. Welding isnt an option. So it looks like the center punch and drill is the only option. What kind of bits should I get? Anyone happen to know how deep into the head the stud goes? I dont want to drill into the head.

You should be able to bridge a 1/4 inch gap with a wire feed welder. This has to be the slickest way to remove a broken stud.

Geezer

[Jacobite]

To add to Geezer's suggestion - use a short bolt instead of just the nut to reach the broken off stud - you can weld "through" it. This is a much easier solution than the drilling and easy out. If you are not comfortable with it - try a good welding shop, I'm sure they will have done it before.

[Toolmaan]

If you do drill it out use a good sharp left handed drill bit. A lot of times when you use a left handed bit the stud will unscrew while you are drilling it. Make sure you use a center punch and punch it right in the center. I work on cars for a living, We will remove broken bolts for people and I'm sure most motorcycle shops will do the same, if you are uncomfortable doing it I would have a pro do it for you, because one little slip and it could cost a lot more to get fixed.