Broken exhaust stud, how to remove?

[Whosthedaddy]

Found the reason for a blowing exhaust, thought the stud had come loose but no it had sheared off!

https://p1.bikepics.com/2014/03/27/bikepics-2654848-full.jpg

Bearing in mind that's a c90 style pit bike engine on the monkey and the stud itself is only m6 sized in diameter, how the hell to tackle it?

The stud is flush or even countersunk in the hole so cannot cross mark for a screwdriver.
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[P.addy]

No help at all but mine did just that. I gave up trying to remove it, too fucking hard!

[c_dug]

Your options are either an easy-out, with questionable results for lots of people. Or spark erosion if you can find somebody to do it for you.
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I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

[c_dug]

You are very near me on the bcf map, I think I have some very chunky easy-outs at work if you want to borrow one.
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I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

[bugeye_bob]

can you not get in with a cordless and 1 or 2mm drill to start it off, then build up until you can get an eezi it out in,failing that your drilling the lot out and heli-coiling it .

these are the eezit out type thing I mean.

https://www.screwfix.com/p/stud-extractor-set-8-pieces/20084

[truslack]

Centre punch and drill it, should even get away without helicoiling it if you get dead centre and increase drill bit sizes till the thread of the bolt collapses.
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Current: Suzuki RG 125 Gamma, Honda H100, Triumph Tiger 800XC, Suzuki SV650 (minitwin)

[Whosthedaddy]

[Whosthedaddy]

[gavcarter]

Remove the rest of the exhaust and it appears you have a few mm sticking out ( once exhaust collar is off ) you can:

A put a hacksaw slit in it and try remove with a flat bladed screwdriver.

B Weld another 6mm bolt onto it and unscrew it like that

C file or grind a flat on each side and get it with a pair of mole grips.

Warming the engine first usually helps to loosen them

[c_dug]

The collar is off, you can see it in the corner of the picture.

I wouldn't buy a cheap easy out having had issues before. They're bloody hard metal to try and drill out when they snap
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I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

[Whosthedaddy]

[Whosthedaddy]

[gavcarter]

[Rogerborg]

Dodgy bodger that I am, I wouldn't try anything other than a centre punch and drilling that out very carefully to 5.5mm before trying a stud extractor to get the remnants out.

At that, it's a stud, not a bolt, so I imagine it's snapped when trying to take the nut off because it's now a part of the head for all practical purposes, so I'd order a helicoil before I started.
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Biking is 1/20th as dangerous as horse riding.
GONE: HN125-8, LF-250B, GPz 305, GPZ 500S, Burgman 400 // RIDING: F650GS (800 twin), Royal Enfield Bullet Electra 500 AVL, Ninja 250R because racebike

[Whosthedaddy]

I've never been lucky when it's come to mechanics or anything of a fixing nature but on this instance not my fault.

I believe I lost an exhaust nut due to vibrations and this then out pressure on the other stud and snapped it off. I swear I was nowhere near it.

Screw fix is 2 miles away so will pop in there for a quick look at some extractors
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[truslack]

Note, extractors are very hard to drill out when they snap
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Current: Suzuki RG 125 Gamma, Honda H100, Triumph Tiger 800XC, Suzuki SV650 (minitwin)

[Raffles]

[........................]

Forget the extractors. Try a left hand drill bit, you never know, it might spin out as you drill it.

[Whosthedaddy]

[groovylee]

The last one I had like that I ended up drilling a small hole in the middle, then hammered a torx bit into the hole and it came out. Kind of like an easy out, but more likely to round off than snap.

I could've just been lucky though. As said already, heating the area up May help break any bond between it and the head first. The drilling adds a bit of heat, and then hammering the bit into it might free it off a bit more.

Hope you get it out ok
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Past - 1988 honda revere 600, 1996 kawasaki gpz500s, 1999 Yamaha R6

Current - 2002 Aprilia RSV1000R & 1999 Kawasaki ZX6R

[Whosthedaddy]

[A100man]

If you end up trying to drill it buy a de Walt Extreme bit from Screwfix.
Super sharp lets you go steady with your drill/driver..

Good luck

[raesewell]

Drill it out with a left hand drill
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Yamaha FJR 1300 Normanton West Yorkshire

[........................]

[misscrabstick]

The secret in getting this out is accurate drilling, start off with centre punching a dot smack in the middle, drill out the stud with a 3mm drill bit, then a 4mm then a 4.5 mm, get a quality torx screwdriver bit of an appropiate diameter and hammer it into the hole, ( needs to be a tight fit) unscrew the stud with a spanner on the hex of the bit, or a socket. Note that heating the area of the head around the stud will help a lot.

Sometimes though they are just too stuck, if your drillings are accurate and centre go up to a 5.0 mm hole and retap with a tap to restore the thread to 6mm.

Don't be afraid to remove the head, it will make accuracy a load easier whilst drilling.