650 Maxim - Broken Exhuast Stud??

Earlier today I noticed it sounded like my bike had a exhaust leak and the right pipe/muffler was rattling, and I found this:

It looks like the a bit of the stud with the nut on the end broke right off?? Please tell me the other end of the stud is threaded and can be taken out, thank god I recently bought another bike because this junk was my ride to work...

 

You will have to carefully remove nut on the opposite side slide flange down , and see if anything is left of the stud. If your lucky you can get a set of extractors find the one and put it over stud and remove it. I have 3 sets of these expect to pay between 20 to 50 $ but they are worth it. These fit into a 1/4 inch ractchet or 3/8 and a short extension ...you will have trouble with vise grips unless you pull whole exhaust . Cheers

 

It will be better to pull the exhaust off. It will make getting it out in one piece easier.
If there is enough threads there put 2 nuts on it and tighten together to make a jam nut. Most likely the stud is corroded in the head and frozen in there. Heat the head around the stud with a propane torch to help break it loose. In this case heat and penetrating oil will be your friend. Once it loosens don't keep turning it, loosen then tighten, loosen then tighten. keep working it back and fourth and with luck it should come out.

 

Heat, apply candle wax, allow to cool, repeat a few times....then you can try to extract the reaminder of the stud. Slow, patience. and watch for the stud to begin wanting to twist; you do not want to break it off further.

 

Damn I have the same problem one of the bolts actually snapped 2 two places - I got part of it out but there is still a piece inside the engine hole about 5mm in..

My extraction bits are all too big so I'm going to run to harbor frieght tmw - I'll see if I can document this for you -- as others have said penetrating oil is good stuff and don't force it too much else you'll do what I did. Although really I never felt it snap when turning so I think it was already just brittle or snapped inside anyway.

 

Also to answer your question - the "bolt" looks like this:



The "nut" comes off as you probably know.... and the other end threads into holes on the engine.

This is the one I took out of the other side so I could get the snapped one off and was very excited I got it out until I noticed it was shorter on the left side than this one lol.

Charcal has replacements here:

http://www.xjbikes.com/forums/threads/xj-parts-catalog-section-f-exhaust-system.44639/#post-395088

 

While i was looking - came across this - pretty good deal don't you think?

https://www.harborfreight.com/60-piece-sae-metric-tap-and-die-set-35407.html

 

Thanks for the info, and damn that tap and die set is a steal! I have been needing one anyway, I think I will be making a run to HF soon!

 

Woohoo houston we have lift-off - I mean screw-out...

I think I actually deserve some kind of MacGiver award for this one - The problem was this was in the outside hole on the second pipe which made it a royal pain in the ass to get a drill in there and i really didn't want to take off the whole exhaust.

I do have a HEX extension from my cordless drill but the only extraction driver I could find that was small enough and designed to get into a small drilled hole in a bolt (instead of a stripped screw-head) and in this little engine hole, was basically a drill bit style and does not have a hex end. Nice set though from HF:



So I finally came across these little counter-sink drill bits




cool thing here is the bit is held into the body that has a HEX end on it by an allen-wrench screw and what-do-you-know the number-1 extraction bit just fits in the #12 counter-sink body



So back to the bolt in here:



I left this little fecker soaking in PB-Blaster penetrating oil over-night and all day spraying it every now and again. Managed to drill a hole in the middle(ish) of the bolt using my HEX extender and these titanium HEX bits



Then I danced around the bike 5 times, sacrificed a goat and gave it a shot with my extraction rig-up.. and...



Now if only USPS hadn't lost my package of new bolts from Charcal I'd be riding instead of wring this!

 

Newbies, pay attention: the goat dance is the important part.

 

Glad you got it out. Your experience is not the same as 95% of the others that go that route. You had a little luck there too.

 

Thanks you sir - I'd like to see the extensive research and statistical model you're referencing for your 95% I do have quite a bit of experience with these things so as much as this was a very tricky one I've done it a few times and have a "feel" I guess for it so, yes I did have a little luck but experience combined with determination and macgiverism got it done. Biggest thing here like most things in life is about preparation - I got the engine warm and 2 days of penetrating oil - without either of those the chances of something snapping again when coming out are drastically increased ( I don't have reliable date to give you a number here ).

I can however testify that the a good goat dance never hurts - well unless you're doing it wrong

 

No research, but if I had a dollar for every thread I read on here about an "EZ Out" snapping I'd be able to buy another bike. You're correct on the preparation part! Your pics are like watching HG TV, broken stud/kitchen remodeled in 30 min.

 

The trick to sucessfully extracting broken fasteners, is years of practice in failing to extract broken fasteners.
It is one of the few mechanical procedures that really does require a long apprenticeship.

 

A friend of mine told me he had success sacrificing a lamb in place of the goat but I wouldn't risk it myself.

 

That's a seasonal thing. Lamb in the spring, goat in the fall.

 

You might want to print out the tracking info from the USPS website and stop by your local post office and ask them to get on the phone to Dulles and ask what's up with the delay.......

 

all we need is a piece of duct tape, a burnt match, one of those wayward felt pads off the base of some thingy and a multi-tool... then we can make you a proper MacGyver Award.

 

I finally got the replacement parts from charcal along with parts to fix the oil leak from my Tach cable - so I killed two birds with one stone and all fixed now and what do you know - no more smoke coming from my exhaust header and no oil leaking from the tach cable hole - - I might wash her now and actually go for a ride