I constantly kick myself for not removing my original, rusty exhaust studs when my heads were off a couple of seasons ago. My bike is somewhat apart right now, and the pipe is off. When it goes back together, it will be with very nice stainless exhaust clamps and nuts, which will really highlight each rusty stud.

Am I asking for lots of trouble if I try to extract the studs now? I would really like to replace them with stainless. Actually, one of the studs came out with the nut this time around (which has never happened before). I tried hitting one with some Liquid Wrench, then double nutting to attempt removal, but it didn't seem like it wanted to budge and I really didn't want to break it.

Any "relatively safe" methods to try?

 

Try some heat on it, heat gun won't screw up the paint, if you can get it to budge work it back & forth a little. Use your judgement but it takes quite a bit to snap one off, if no luck you use a wire wheel in a dremel & buff it up, good luck.

 

Soak with penetrating oil over night, the heat the area around the head and try extracting it with the double nut trick. Use a heat gun and heat surrounding area evenly and gently. You can use a torch if you’re very careful, just don’t warp the head from heating one spot.

 

Weld a nut on the end of the stud. The heat will probably free it up and you'll have something to turn it out with. You can apply a wax candle to the base of the stud as it cools and it should draw in the wax and lube the threads.

Stainless hardware in aluminum promotes corrosion of the aluminum. You're better off with cadmium plated steel. If you insist on stainless, make sure the threads are spotless and put something on it that will withstand the heat and prevent moisture from getting in to the threads.

 

Use 2 nuts. Sung them together so they "lock" themselves on and then use the one furthest in to extract the stud.

 

Play it safe and do the clean up with a Dremel. That guy had a good idea.

 

I suppose it depends on just how bad you want them gone. Worth the risk of breaking and having to drill & helicoil? There are drill guides available to make repair easier but access inside the frame can be a problem. I'd be prepared to remove the heads,..

If I were in your shoes, I'd probably clean them up and brush a bit of high temp silver paint on them after the nuts are torqued.

Mine are currently just like yours. It's only a minor irritation so I don't plan to mess with them until the heads come off. But that's just me.

 

Ditto ∆∆∆∆

 

I am sure you guys have stud removers at the dealership. They do work well but if the don't work then the stud is destroyed. I like what the other guys told you about the double nut welded.

 

Don't meet trouble halfway, every time I have, it led to regret. Clean it up and leave it alone. When it comes time to to do engine work and the heads are off, replace all 4.