broken exhaust studs

[h7thl]

hi all as per title i have 2 broken exhaust studs what is the best way to get them out as the engine is still in the bike and i dont fancy trying to take the engine out any help would be great 

[Deefer666]

If they are on the middle ports, chances are that you have to take the lump out

[Candyman]

OK don't do this  :rolleyes


I had two middle studs snap on me.  I laid the bike down on a mattress to get easy access, tied the wheel up and very very slowly drilled the studs out starting with a very small high quality metal drill bit, increasing the size of the drill bit as I made progress.  Did take a week of careful drilling and lots of cups of tea and nerves.  Had to make sure I was drilling straight  Replaced with new studs ordered from AJSutton.  As I say don't do it.....unless you you have lots of tea!

[Jules-C]

Where are they broken, flush with the cylinder head? In which case engine out. If they sticking out from cylinder head and have some thread but not quite long enough to get through the exhaust clamp a temporary fix might be possible with furniture connector nuts like eBay item 281189197636

[Buzz]

Where are they broken, flush with the cylinder head? In which case engine out. If they sticking out from cylinder head and have some thread but not quite long enough to get through the exhaust clamp a temporary fix might be possible with furniture connector nuts like eBay item 281189197636

Or rivet nuts

[HarryHornby]

take it to a local garage........... I did, after focing my attempt up!  But then I'm a very basic mechanic.

[hightower]

I know engine out sounds daunting, but I did it myself and I class myself as basic when it comes to these things. I used the opportunity to give my head and block a much needed paint, as well as lapping the valves and changing those stem seals. That's a job I class as never needing to do again now, so all good.

[scottishbybirth]

I snapped three bolts at the block this year. My solution was to use the spare lugs either side of the original lugs drilled and tapped fresh holes to take new studs. I ground the old studs flush. Admittedly the exhaust manifolds now look odd being 90degrees out of since to the outsides but a quick and easy fix. I count myself very lucky to have not caught any internal oil/water feed pipes but 3000 miles later with no loss of oil or water I must have been very lucky. And no I don't know the lottery numbers for next week he he.

[Kentish]

Engine out is the only way.

[Paulfzs]

engine out?


i did mine with the engine in...

this one is the middle one on the right hand side looking at the bike.. bit tight but still pretty easy..
start with a 2mm drill bit work up by .5.. took me about hour and half - 2 hours

[Kentish]

to do a proper job the engine has to come out. its easy taking the lump out

[Paulfzs]

to do a proper job the engine has to come out. its easy taking the lump out

i did a propper job with the engine in :S


am i missing something lol

[unfazed]

engine out?


i did mine with the engine in...

this one is the middle one on the right hand side looking at the bike.. bit tight but still pretty easy..
start with a 2mm drill bit work up by .5.. took me about hour and half - 2 hours

Paul

It that a GS1000S or GS1000 with S panels on the left in the picture?

[Paulfzs]

[quote author=Paulfzs link=topic=13961.msg174889#msg174889 date=1416868396]
engine out?


i did mine with the engine in...

this one is the middle one on the right hand side looking at the bike.. bit tight but still pretty easy..
start with a 2mm drill bit work up by .5.. took me about hour and half - 2 hours

Paul

It that a GS1000S or GS1000 with S panels on the left in the picture?
[/quote]


GS1000

[Kentish]

are the Boxeye and foxeye the same frame? Its impossible to get flush on the middle studs on a foxeye . The frame is in the way

[unfazed]

Use left hand drill bits,

Frame down tubes and cross bars in the that section are the same.

[Paulfzs]

he has the boxeye and the frame bar that goes across is in the way a little bit but if you have a slim drill itll fit in with plenty of room

[Gingernutz]

When mine broke the dealer called in an engineer who drilled them in place  - he spends half his life patiently drilling these out

[Dave48]

Easier to remove rad & hoses for access to broken studs than to remove entire engine. It is possible with care & patience to drill these out in situ-you need,as said, a fairly narrow drill & long drill bits to bypass frame brace. Get comfortable before starting to drill & get plenty of light on the area.

[MC680x0]

how do these things break anyway; I've never had studs break on any bikes I've owned. Is this a fizzy only issue ???  does spraying the header nuts for a week - before attempting removal - with WD not help?