What next? Advise please...

This morning I went out to fix an exhaust leak I found that was at the bottom of the head pipe where it goes into the collector and when I went to look at it I noticed I was missing an exhaust stud where the head pipe attaches to my motor. Tried putting one in and couldn't get it to screw in. So I took the head pipe off and still wouldn't go. That's when I seen it. 8O Somehow the old stud broke off in the engine. :cry: Of course it had to be the one off the #2 cylinder. You know the one right next to the frame. :evil: I took the bike to my buddy who is a machinist and he said he didn't want to do it with the motor in the bike because there is no room to work. The one question I have is there an easier way to fix this short from pulling out the motor? Then to top it off I went to my shed to get a tool and the drawer it was in falls apart. WHAT NEXT?? Any ideas would be appreciated.

 

Re: What next?

Buy a new tool box.

 

Re: What next?

Thanks! :roll:

 

Is there any part of the bolt protruding from the head? If so, you might be able to weld a nut on top and try to unscrew it. The heat from the weld will help loosen the thread (make sure you disconnect your battery and ignitor before welding though).

If not, careful drilling and an ezi-out ???

 

That is the problem it was broken about an 8th of an inch inside.

 

Don't bother with the easy out, if it snaps you are in deep do dos, carefully drill it out & re-tap, use a 4.8mm drill.

 

Re: What next?

Sorry. Couldn't help myself. Good luck getting the stud out.

 

If the Bike has got low miles on it and runs good ... you might want to consider Killing a Lot of Birds with ONE Big move.

Take-of the Cylinder Head.
Remove ALL the Exhaust Studs and ALL the Intake Studs.
Run a Tap in all the Holes after Repairs are concluded.
(The Intake Manifolds Fasteners may require Machine Work to extract them.)
Clean-out the Exhaust Ports
Remove the Carbon Deposits
Install New Valve Seals
Lap the Valves
Clean the Piston Crowns
Put it all back together using High Quality Hardened Studs and Fasteners in Re-Tapped Holes treated with an AntiSeize Compound.

 

Well after a couple hours this is what I have.
It was actully a lot easier than I thought and the motor was lighter than I thougt. I was abel to pick it up and carry it and put it in the back of the truck with no assistance. I a m going to take it to my buddy who is a machinist and have him remove the stud that is broke off. I had 4 other bolts that were stuck in there but with a little patience was able to get them out as well. Thanks for the other advice Rick. I will look into it. I just got the bike road worthy after many years of waiting. So I will probley just get the stud removed and maybe a couple other things that can be taken care of while the motor is out. I just want to get to riding now. Here is a pic of the problem also. It is the stud on the bottom of the second port in pic. You may not be able to see it to well. My camera is not the greatest.

 

While you have that thing out, have it Soda Blasted!!!!

 

I agree.
Soda Blasted or one of the Non-destructive Media.
Walnut Shell or Plastic Beads