-Just in case this happens to somebody on their V-twin and they need one more option. . . .

I was removing the exhaust on my son's 4-wheeler and snapped an exhaust stud. I searched a few forums and saw lots of suggestions. I tried several, but only one worked. Here was the winner:

After removing the exhaust pipe flange, I had maybe 1/4" of the stud sticking out of the head. First, I sprayed the stud with PB Blaster. Then, I took a 12-point socket with an opening a little smaller that the diameter of the stud and whacked it onto the stud with a hammer, basically cutting splines into the stud. Then, I heated the head (aluminum, which I'm guessing expanded faster than the steel stud) and and touched a tea light to the stud (only candle my wife would let me destroy), letting the wax chase up the threads into the head and act as a lubricant. I put my ratchet handle into the socket and twist, twist, twist: the stud came right out.

 

You might wanna mention the method used to heat the aluminum. A heat gun would be preferable. Aluminum will melt.

 

Good point. I used a simple cheapo propane torch. I wouldn't use acetylene or even map gas, but I figured the propane for a minute would be safe -- and it seems to have been. I've unstuck steel bolts in aluminum many times with a propane torch without incident -- but never a stud like this. I think my heat gun would take a long time, but I'll give t a shot next time.

 

What is PB blaster?

 

http://www.acehardwaresuperstore.com...70.html?ref=42


Google is a wonderful tool.

 

interesting procedure...