Broken Exhaust Stud
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Intermediate
Joined: Jan 2018
Posts: 36
Likes: 3
From: Kelowna
Broken Exhaust Stud
Ran into a bit of a setback hoping someone could give me some information or guidance on my issue...
Just recently removed my header on my 2017 Road Glide Ultra to install new header, got new header on bike and doing final torque on exhaust header studs. Exhaust stud snapped off and broke flush with the Jug..
Anyone have any experience with this happening, how to remove properly and safely? Bikes under warranty also with extended, does a guy try to take to dealer to try under warranty ? Fix personally? Any suggestions or help would be awesome! Thanks in advance.
Just recently removed my header on my 2017 Road Glide Ultra to install new header, got new header on bike and doing final torque on exhaust header studs. Exhaust stud snapped off and broke flush with the Jug..
Anyone have any experience with this happening, how to remove properly and safely? Bikes under warranty also with extended, does a guy try to take to dealer to try under warranty ? Fix personally? Any suggestions or help would be awesome! Thanks in advance.
HDF Community Team
Joined: Jun 2006
Posts: 12,776
Likes: 2,607
From: san antonio
That's a tough one but it happens too often. Looks like the rear cylinder which provides a bit more working room but most likely you will have to remove the head to remove the broken stud. Having said that you could try finding and "edge" in the broken stud that would allow you to try and use a chisel to catch the edge and tap on the broken stud to see if it is in so tight it won't back out any at all. I have done this successfully a couple of times but did have a bit of the broken stud exposed above the head surface. Sometimes, once loose, a broken stud can be backed out enough to Dremel a slot that will allow final removal with a screw driver. Or if you can back out enough to weld, maybe even JB weld, a nut on the broken stud and back it out that way.
There is a special jig for drilling broken exhaust studs out but having never had to use one, I don't know if the jig can be attached and used properly with the head mounted to the cylinder. If I were in your shoes, I would remove the head and take it to a machine shop and have a machinist remove the broken stud. Just need a new head gasket. If you decide to go that route, be careful removing the head and try not to disturb the cylinder to case joint where the o-ring sits. Get a couple of 1/2" PVC couplings and as soon as the head is off, use the couplings as spacers and secure the head at opposite corners with the head bolts.
There is a special jig for drilling broken exhaust studs out but having never had to use one, I don't know if the jig can be attached and used properly with the head mounted to the cylinder. If I were in your shoes, I would remove the head and take it to a machine shop and have a machinist remove the broken stud. Just need a new head gasket. If you decide to go that route, be careful removing the head and try not to disturb the cylinder to case joint where the o-ring sits. Get a couple of 1/2" PVC couplings and as soon as the head is off, use the couplings as spacers and secure the head at opposite corners with the head bolts.
Thread Starter
|
Intermediate
Joined: Jan 2018
Posts: 36
Likes: 3
From: Kelowna
That's a tough one but it happens too often. Looks like the rear cylinder which provides a bit more working room but most likely you will have to remove the head to remove the broken stud. Having said that you could try finding and "edge" in the broken stud that would allow you to try and use a chisel to catch the edge and tap on the broken stud to see if it is in so tight it won't back out any at all. I have done this successfully a couple of times but did have a bit of the broken stud exposed above the head surface. Sometimes, once loose, a broken stud can be backed out enough to Dremel a slot that will allow final removal with a screw driver. Or if you can back out enough to weld, maybe even JB weld, a nut on the broken stud and back it out that way.
There is a special jig for drilling broken exhaust studs out but having never had to use one, I don't know if the jig can be attached and used properly with the head mounted to the cylinder. If I were in your shoes, I would remove the head and take it to a machine shop and have a machinist remove the broken stud. Just need a new head gasket. If you decide to go that route, be careful removing the head and try not to disturb the cylinder to case joint where the o-ring sits. Get a couple of 1/2" PVC couplings and as soon as the head is off, use the couplings as spacers and secure the head at opposite corners with the head bolts.
There is a special jig for drilling broken exhaust studs out but having never had to use one, I don't know if the jig can be attached and used properly with the head mounted to the cylinder. If I were in your shoes, I would remove the head and take it to a machine shop and have a machinist remove the broken stud. Just need a new head gasket. If you decide to go that route, be careful removing the head and try not to disturb the cylinder to case joint where the o-ring sits. Get a couple of 1/2" PVC couplings and as soon as the head is off, use the couplings as spacers and secure the head at opposite corners with the head bolts.
Thanks for the response DJ, thinking its gonna go into a shop. Cheers
Seasoned HDF Member
Joined: Apr 2010
Posts: 9,570
Likes: 7,942
From: Long Island, New York
That sucks, I would not attempt to do it myself, probably just make it worse. Bring it to a shop. I also agree that if I am taking a motor apart it is likely that stock parts are not going back in. Good luck.
Banned
Joined: Sep 2009
Posts: 3,569
Likes: 624
From: deland,florida
DONT attempt to drill it out your self,if its under warrantee,put the stock ex system back on & say it happened by itself.but don't try to fix it without the proper machines & method.we get a lot of heads in here to repair ex studs after their all munged up by someone trying to get them out & basicly taking a fairly simple machine job & turning it into a big,fairly expensive mess
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Road Warrior
Joined: Jul 2012
Posts: 1,566
Likes: 55
From: Londonderry, NH
DONT attempt to drill it out your self,if its under warrantee,put the stock ex system back on & say it happened by itself.but don't try to fix it without the proper machines & method.we get a lot of heads in here to repair ex studs after their all munged up by someone trying to get them out & basicly taking a fairly simple machine job & turning it into a big,fairly expensive mess
Snapped a rear stud a while back. Tried to fix it on the bike. The hardened drill bit (for an extractor) snapped off in the stud. There just wasn't much room to work on it. I wasn't able to do anything with it at that point.
I ended up taking it to a local MC performance and machine shop and they fixed and didn't charge much for the job (I was a customer). They did it without removing the head.
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HDF Community Team
Joined: Jun 2006
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From: san antonio
Last edited by djl; Jan 5, 2018 at 08:43 AM.