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.

 

 

While it’s apart do a big bore kit and high flow heads, it’s just a little more money. Trust me, you’ll be glad you did.

 

We are in constant repair of heads from individuals and shops, here.
Scott

 

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.

 

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

 

That's good advice from prodrag1320.

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.

 

ok...so are the exhaust studs removable? my exhaust is presently off and the studs looks a little buggered so I would like to change them if possible.

 

Yes but maybe just running the proper size thread restorer, or dye, will "un bugger" the threads and removal is not necessary. If not, double nut the exposed threaded section and it should back right out. If you get some resistance, apply some penetrating oil and let it sit for a while before trying to back back it out. Use the same double nut technique to install the new studs.