Exhaust stud removal
Grand HDF Member
Joined: Apr 2007
Posts: 3,727
Likes: 3,072
From: Brighton, MI
Last I heard about 10 ft lbs of torque are used for those studs.
The issue is: they are good and stuck from how long they have been in there, the heat cycles over the years, the oxidization of the steel stud in an aluminum head. Kind of like a cold weld.
I don't have much faith is getting the penetrating oil in where you need it unless you give it help by vibrating, shock, thermal expansion and then contraction by cooling, etc. You have to disrupt that oxidization "bond" to be able to get the penetrating oil in where it will help.
The issue is: they are good and stuck from how long they have been in there, the heat cycles over the years, the oxidization of the steel stud in an aluminum head. Kind of like a cold weld.
I don't have much faith is getting the penetrating oil in where you need it unless you give it help by vibrating, shock, thermal expansion and then contraction by cooling, etc. You have to disrupt that oxidization "bond" to be able to get the penetrating oil in where it will help.
Road Master
Joined: Sep 2021
Posts: 759
Likes: 936
From: Under the affluence of incahol.
If heat and vice grips etc does not work and the stud ends up broken off flush, as they usually do, you can get a jig online to guide a drill bit to drill it out. Use a left-hand drill bit running in the reverse direction. It tends to unscrew what what is left of the stud as you go.
HDF Community Team
Joined: Dec 2005
Posts: 5,422
Likes: 2,621
From: NC USA
To install new ones, just double nut them, run them in till they're snug (only) take the nuts off and carry on with assembly...
You've gotten a ton of great advice on here. I've done a ton of ugly work like that on all kinds of machinery. Honestly, even with a welder and/or acetylene torch, it's a 50/50 at best you'll get it out while on the bike.That's a mean angle to work around. I recommend you pull the head and take to a general machine shop. have them both removed.
Last edited by t150vej; Mar 4, 2024 at 06:43 PM.
Thread Starter
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Grand HDF Member
Joined: Oct 2006
Posts: 3,665
Likes: 714
From: DFW
I'm working on it now and will give it a go. My first thought and the most likely to happen is do my new favorite thing and remove the head and go to the bike shop or machine shop to have it removed.
Seasoned HDF Member
Joined: Jan 2011
Posts: 157,521
Likes: 57,072
From: Michigan 15 Minutes East Of Hell
A wise man once told me if you don't have time to do it right, you won't have time to do it over ... As mentioned weird angles can make the job difficult ... Good luck ";>)
HDF Community Team
Joined: Dec 2005
Posts: 5,422
Likes: 2,621
From: NC USA
Hang in there 
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Seasoned HDF Member
Joined: Sep 2017
Posts: 12,255
Likes: 4,947
From: England
It is way passed time for me on my 2017 but a guy did suggest every service moving the stud nuts to stop them rusting together. On the 2008 I have here the studs are clean and the I can get the header off easily as I have done it a few times now.