Exhaust Studs

[rac3r]

What's the best/easiest way to remove exhaust studs?
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Bikes : 2006 CBR125R - 2004 Monster 620ie - 2004 ZX-6R B1H - 2005 Monster S2R 800 - 2011 Street Triple - 2009 Streetfighter 1098 - 2014 ZX-6R 636

[DrDonnyBrago]

[rac3r]

Left hand side stud came out with nut still stuck on but on the right hand side (which I did first) the nut snapped but there is still a fair bit of stud sticking out

Also on reassembly doesn't the top half need to be locked with something?
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Bikes : 2006 CBR125R - 2004 Monster 620ie - 2004 ZX-6R B1H - 2005 Monster S2R 800 - 2011 Street Triple - 2009 Streetfighter 1098 - 2014 ZX-6R 636

[Ariel Badger]

Screw a nut onto them and weld it into place. Then hammer it into the head and unscrew it.
The rapid expansion fron arc welding combined with the percussive blows should release it.
WD 40 may or may not help
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Bikers make great organ donors, get 115 on your licence today.

[0l0dom0l0]

I've just done mine and got a few tips for people. None of mine snapped and that's on a 25 miler, so either I did it right of got lucky

First thing I did was start with the penetrating oil early. I started spraying them a month ago, and what a different it makes. Also putting the engine through a few heat cycles with the penetrating oil helps.

I then got a large screw driver and hit every nut with a big hammer with reasonable force. If you get the hammer and screw driver square, then you won't break anything. This breaks all the rust. I then got a good fitting socket and went for it. Every time you are unsuccessful with removing them and apply pressure you are weakening the stud.

Personally, I would steer clear of using heat on the for a couple of reasons:

1. Cylinder heads warp easily and applying that much heat in a concentrated area is not good.

2. The heat will also weaken the stud inside the head, exactly where you don't want it to snap.

I just went for it and I had good results. You can expect a couple of snapped studs but you'd be VERY unlucky if they snapped inside the head. Stud extractors are the best for removing snapped studs so it's not the end of the world.

HTH
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CBT Passed: 30/08/2009, Theory Passed: 31/08/2010, Mod 1 Passed: 6/9/2010, Mod 2 Passed: 13/09/2010. Restriction ended 13/09/2012.

Bikes: 2007 Derbi GPR 50, 1998 Yamaha Fazer 600 (written off), 2002 Yamaha Fazer 600, 1994 CBR 600F, 2003 Triumph Daytona 600, Kawasaki ZX6R J1.....Current: 2006 Yamaha FZ6, 1998 Suzuki TL1000R and a Honda VFR 400 NC30.