broken exhaust stud
Tourer
Joined: Jan 2011
Posts: 401
Likes: 8
Man it sucks H.D. uses such crappy metal in their studs. They s/b stainless steel since they thread into an aluminum head. I spray down the nut and stud with P.B. blaster then heat the crap out of it before I remove them. Had the broken stud problem once, it sucks
Tourer
Joined: Jun 2007
Posts: 292
Likes: 4
From: New Philadelphia, OH
Just take it to a shop. It's not worth the frustration trying to do it yourself, believe me. I had the same thing happen to me and there is just no way to get a drill in there with the frame in the way. If you mess up you'll wish you had pulled the head to get it fixed, not replace it.
Thread Starter
|
Cruiser
Joined: Aug 2010
Posts: 179
Likes: 0
From: illinois
i was taking off stock pipes. i did soak with pb blaster. the other three came off without a problem. the last one didnt give at all just broke right off. i did borrow the jims jig part number 1705-1 to drill it out. im going to remove the front engine mount and either lower it or raise it to gain clearance. removing the head is not an option for me as i dont have the cash to buy all the parts to reinstall it. knowledge wise no problem. taking it to the machine shop is the same in my opinion as pulling the head. cash i dont have. im going to drill it out on friday night or sat day. i have the tap to run in once im done i just f;$#ing hate drilling out bolts. had to do it too many times at work. mostly on exhaust studs in heads. wish me luck.
Road Master
Joined: Feb 2012
Posts: 1,217
Likes: 6
From: bfe
i was taking off stock pipes. i did soak with pb blaster. the other three came off without a problem. the last one didnt give at all just broke right off. i did borrow the jims jig part number 1705-1 to drill it out. im going to remove the front engine mount and either lower it or raise it to gain clearance. removing the head is not an option for me as i dont have the cash to buy all the parts to reinstall it. knowledge wise no problem. taking it to the machine shop is the same in my opinion as pulling the head. cash i dont have. im going to drill it out on friday night or sat day. i have the tap to run in once im done i just f;$#ing hate drilling out bolts. had to do it too many times at work. mostly on exhaust studs in heads. wish me luck.
Elite HDF Member
Joined: Apr 2010
Posts: 4,990
Likes: 9
From: Marina del Rey
You'll destroy the head if you just drill and tap to original size. Even using a guide bushing your hole may not be coaxial, leaving some part of the broken stud which must be removed prior to chasing the original threads.
Last edited by lo-rider; May 17, 2012 at 08:52 PM.
Road Master
Joined: Feb 2012
Posts: 1,217
Likes: 6
From: bfe
i believe he is going to use the jims guide and an easy out and then tap it , id use a left hand 12 inch long drill bit and i bet stud would back out while drilling . the head would not be destroyed if he mess up threads in head he can just put heli coil or steel thread insert in , if he got real wild he could even have head welded . this is not rocket science
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Southpaw Super Glide: A Left-Hand-Drive 1979 Harley FXE Built to Fit the Rider
Verdad Gallardo
The Best and Worst Harley-Davidson Moves of 2025
Verdad Gallardo
Elite HDF Member
Joined: Apr 2010
Posts: 4,990
Likes: 9
From: Marina del Rey
This stuff isn't rocket science, but it's surprising how many amateur bike mechanics can turn a simple DIY project into a jury-rigged patch-job that compromises the bikes integrity.
Road Master
Joined: Feb 2012
Posts: 1,217
Likes: 6
From: bfe
Helicoil's and welding are means of salvaging a part which has otherwise been destroyed. Either repair makes the head inferior and non-exchangeable.
This stuff isn't rocket science, but it's surprising how many amateur bike mechanics can turn a simple DIY project into a jury-rigged patch-job that compromises the bikes integrity.
This stuff isn't rocket science, but it's surprising how many amateur bike mechanics can turn a simple DIY project into a jury-rigged patch-job that compromises the bikes integrity.