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!!

 

Just take it in to Harley. Sure there are ton of tools you could use to get it out but they are sometimes expensive and when used improperly, can just make it worse...

 

 

Over tighten call strong in the back weak in the mind, that's what of my friend used to say. I would check your local shops. Ez out works good

 

Yeah, that really explains why I have broken one while taking the nuts off of it. They just get brittle and sometimes the nuts seize up on them.

I don't know how much mechanical ability you have, but you have a choice or two.

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.

 

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.

 

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

 

After all the little tricks fail to remove it, wire feed a nut to the stud and unscrew it.

 

Best advice above and like stated, easy outs are brittle and extremely hard. If you break the easy out, you have bigger problems.

Like suggested in previous post, you may want to take to an independent shop to avoid warranty issues.