Help removing broken exhaust stud

[Rick1138]

Hi all,

i found out why my bike was vibrating...it started to get noisy along with this!!

The left side rear cylinder is leaking from the exhaust header. After having a look i found that the nut had fallen off one of the studs and needed a replacement.

However after stripping the tank and rear panels i got a right look at the exhaust, the bolt has actually been broken and never sorted (probs because of similar issues i am having, shall explain in a sec!), this meant that the oval shaped clamp was pressing against the other stud and had wedged against it.

I found that i had to remove the exhaust and get the manifold of the back 2 cylinders.

All the exhaust studs came off fine, apart from the one that was wedging the oval clamp.

So as it came off, it broke, the nut is dirty inside the break so i assume it was already partly broken!

So i now have the 2 studs from the left rear cylinder at about a centimeter long stuck in the engine.

I have tried draper stud extractors but they were utter garbage (gonna get my cash back on them as they simply dont grip things, i tried spare nuts in the garage, and they don't grip at all well!)

Is there any way i could get the studs out without having to remove the entire rear assembly or the rear cylinder bank/cylinder head to go at it on a bench.

AS removing the cylinder casing is just not going to be fun, especially holding piston ring assemblies etc together.

cheers for any advice all.

[viper_biker]

Can you get 2 nuts onto it and lock them against eachother?

[Rick1138]

unfortunately not, i can with one of the bolts, but as its the rear cylinders there simply isn't room to maneuvere spanners.

and the other bolt is stripped, as its been left after someone trying to do something with the exhaust and broke it, yet never fixed it.

[viper_biker]

The only wat I was able to take the little stubby part of the exhaust off the rear cylinder was to remove the sub-frame and rear cylinder head but I was fortunate enogh to have all the threads intact.

I have used a method of hammering a socket that's slightly smaller than the bolt diametre and unscrewing it that way, but that doesn't always rowk. I hope you can get it sorted.

[Rick1138]

the little stubby exhaust, y piece at the back has come off fine, its just the studs i am trying to remove now.

[viper_biker]

Smack a smaller socket onto there and take it from there. To ease access you'll need to drop the shock out too, but that will involve the removal of the exhaust if it's a standard system.

[Rick1138]

just curious, but how will a smaller socket help me remove the stud from the engine?

as i have nothing to grip the stud with, i am struggling for idea, bar removing the engine and trying that.

[viper_biker]

The smaller inner diametre of the socket will creat a hexagonal shape on the bole so that when you fit a ratchet to the socket you can undo the stuck bolt. It is a crude but effective method that I have used on a number of occassions.

[Rick1138]

cool i shall give that a try, cheers

[MickCheese]

Before trying to remove the stud give a good soaking with 'plus gas'. Most decent car repair shops should sell it. far better than WD40.

Mick