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.
Last edited by sixfour; Jan 2, 2018 at 07:01 AM. Reason: Spelling error
Club Member
Joined: Apr 2013
Posts: 5,868
Likes: 3,845
From: Cape Cod
REAL pia........left mine broken for the last few years as I tried drilling and EZOUT.......EZOUT snapped flush..........recently took head off to take it to a machine shop.
CAREFUL of EZOUTS.......they are brittle!!
DOUBT you will get a shop to do it under warranty.......all your fault!!
Good luck!!
CAREFUL of EZOUTS.......they are brittle!!
DOUBT you will get a shop to do it under warranty.......all your fault!!
Good luck!!
Tourer
Joined: Feb 2016
Posts: 349
Likes: 83
From: Florida
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.
You had a warranty and an extended one....once you installed an aftermarket or catless oem head pipe it was voided on the spot and you didn't even know it.Do not go anywhere near a harley stealer until you get it off and the sticker back on.Of course if it was tuned with anything other then the hd se tuner it won't matter.
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.
If the header you were taking off was installed by the dealer or is the stock header, put it back on and take it to the dealer. Tell them you noticed the stud was broken and let them deal with it.
If the header you took off was aftermarket and you have tuned the bike with something other than a SE tuner, then your warranty could be void. You can try the dealer thing, but you might end up paying the bill.
Don't try to remove the stud yourself. This is seldom successful or it you do get it out you end up defacing the head. TAKE IT TO A MACHINE SHOP. I don't know how they do it, but they can get broken studs out without screwing everything up. Talk to them and see if they can do it with the head on the bike. They may want the head removed, so now you're either going to have to have that done or do it yourself. Like I said, I don't know your capabilities so you will have to make that choice.
Cruiser
Joined: Jun 2008
Posts: 160
Likes: 40
From: San Diego
Like others have said, dealer or a good machine shop. I made the mistake once thinking that the torque spec in the shop manual was foot pounds instead of inch pounds, so I kept tightening but when I striped the nut I went back and reread the spec and realized my mistake, fortunately I did not break the stud. Not saying this is the mistake you made, but just in case thought I would mention it.
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Road Captain
Joined: Feb 2010
Posts: 541
Likes: 36
usually unless stud was loctited or bottomed out by over tightening once broke no real pressure on them I have removed such with small pic . another trick is to center punch stud and use a left hand drill bit as the drill gets deeper it pulls in loosening direction of stud and I have had them spin right out if its really stubborn an eazy out will work but cannot be twisted to side as they are brittle and will snap. 40 + tears as a tool and die maker come in handy
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Road Warrior
Joined: Sep 2007
Posts: 1,954
Likes: 148
From: Augusta, GA
usually unless stud was loctited or bottomed out by over tightening once broke no real pressure on them I have removed such with small pic . another trick is to center punch stud and use a left hand drill bit as the drill gets deeper it pulls in loosening direction of stud and I have had them spin right out if its really stubborn an eazy out will work but cannot be twisted to side as they are brittle and will snap. 40 + tears as a tool and die maker come in handy
Like suggested in previous post, you may want to take to an independent shop to avoid warranty issues.