Broken Exhaust Stud
Road Master
Joined: Mar 2017
Posts: 760
Likes: 273
From: Olympia, WA
Cut a slot with a dermal tap slot with a hammer and screwdriver or like sixguns says. It will come out.
Grand HDF Member
Joined: Nov 2009
Posts: 4,315
Likes: 1,663
From: Tampa
Bolt up the OEM exhaust back onto the bike and tell the dealership you hear something rattling by the back cylinder...
Seriously, you've got QUITE an uphill battle with this one. Lugging your bike around to have it fixed is a bitch. The last time I repaired that exact issue the head was in a vice and I drilled the old stud out large enough to tap a 1/2"x13 aluminum bolt JB welded in place and cut flush with the head casting, then retapped for a new stud. All EZ-outs can't handle the torque needed to remove that stud. The stud actually uses an interference thread, which is very tight all the way down. It's not a normal 5/16"x18 thread.
Seriously, you've got QUITE an uphill battle with this one. Lugging your bike around to have it fixed is a bitch. The last time I repaired that exact issue the head was in a vice and I drilled the old stud out large enough to tap a 1/2"x13 aluminum bolt JB welded in place and cut flush with the head casting, then retapped for a new stud. All EZ-outs can't handle the torque needed to remove that stud. The stud actually uses an interference thread, which is very tight all the way down. It's not a normal 5/16"x18 thread.
Last edited by Mattbastard; Jan 2, 2018 at 06:58 PM.
Tourer
Joined: Jul 2015
Posts: 267
Likes: 94
From: va
I have never had an issue with an ez out. They have always worked great for me. Every time I heard of someone having a hard time with them is because they didn't use the right drill bit or they didn' drill the hole deep enough so only the tip was grabbing the part being extracted
Seasoned HDF Member
Joined: Dec 2005
Posts: 19,928
Likes: 8,032
From: poway
I have never had an issue with an ez out. They have always worked great for me. Every time I heard of someone having a hard time with them is because they didn't use the right drill bit or they didn' drill the hole deep enough so only the tip was grabbing the part being extracted
I have.. Used to work as an MC mech.. The problem with the tapered EZ outs is that when the are driven in they expand the end of the broken stud/bolt. The rigid extractor places an even load on broken part for a longer distance and does not swell the end. For sure drilling all the way through helps to release tension on the stuck part in either case.
Grand HDF Member
Joined: Nov 2009
Posts: 4,315
Likes: 1,663
From: Tampa
I have never had an issue with an ez out. They have always worked great for me. Every time I heard of someone having a hard time with them is because they didn't use the right drill bit or they didn' drill the hole deep enough so only the tip was grabbing the part being extracted
There's a reason Jim's makes a jig for drilling out exhaust studs.
Seasoned HDF Member
Joined: Jan 2011
Posts: 157,524
Likes: 57,080
From: Michigan 15 Minutes East Of Hell
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Seasoned HDF Member
Joined: Jan 2011
Posts: 157,524
Likes: 57,080
From: Michigan 15 Minutes East Of Hell
I have.. Used to work as an MC mech.. The problem with the tapered EZ outs is that when the are driven in they expand the end of the broken stud/bolt. The rigid extractor places an even load on broken part for a longer distance and does not swell the end. For sure drilling all the way through helps to release tension on the stuck part in either case.
Thread Starter
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Intermediate
Joined: Jan 2018
Posts: 36
Likes: 3
From: Kelowna
Thanks Robbie, I think thats best option. Any idea what the draw back or consequences would be having it fixed from the dealer it was bought at? Would you just have to pay the bill upfront for the repair, or is your warrenty voided from that date on? Removing my 4 year warrenty...? I am unclear on all the rules with warrenty. Thanks