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Went for a nice ride today. 2005 Sportster 1200 Roadster. About 20 miles in started noticing the engine sounding a little off, especially at idle. Rode back home and got to looking around and noticed the exhaust flange on the rear exhaust just hanging without being bolted on. Nut must have vibrated loose. Then I noticed one of the studs was completely missing. Took the pipe off and sure enough it's sheared off. Not even flush, but recessed probably a good quarter inch.
Doing some searching around the forums it seems like the general consensus is not to attempt to remove using an extractor and rather to take the cylinder head off and take it to a machine shop to have them remove it. Seems smart. Deep enough in there and I'm an inexperienced enough mechanic that I don't think I want to attempt it myself anyway.
My question is, can I bolt the exhaust on using the remaining stud and still run it for the rest of the season if I'm diligent about checking the nut since they're obviously prone to vibrating off? I'm currently in the process of a top end rebuild on my suzuki engine so this is my sole ride right now. I've only just started riding this season due to title/registration issues, and since it's almost July already the riding days are numbered here in Michigan. I'd hate to have my riding season cut short just as it was getting started and it would be nice if I could wait until the snows come and I'm not riding anymore to get the cylinder head off.
Last edited by rocksandhammers; Jun 29, 2021 at 04:06 PM.
Reason: Forgot to add bike year/model
If you were able to take that picture at that angle then a mechanic or machinist should be able to remove it in little time.
No mention of miles or history so perhaps it was broken for a while.
I would not ride it like that.
Not as easy to remove as a protruding stud because there is nothing to locate a centering guide to . Drilling steel studs in aluminium castings may not end well unless someone really knows what they are doing . Good luck with the other three .
I'd say you could drill that out, easy out it, with some heat.
There is a ton of posts on here with stories of broken easy outs.
The crux of the problem is being able to drill exactly in the centre and straight. For a DIYer it generally doesn't happen.
There is a guide available, as the other stud is still there, to accurately position the correct size tapping drill bit. They are expensive. A machine shop ought be able to drill the hole perfectly as well.
Seems just as successful, even easier, than removing the cylinder barrel.
Question being can you get the drill angled correctly while the motor remains in frame.
If not, then go next level and remove the cylinder but still use this guide.
I am not sure if guide/ DIY tools/ gaskets or machine shop is less cost.
I'll add to "never use an extractor", I've personally never seen one work and they break even on low torque bolts.
I'd consider it lucky on which stud broke, maybe a reputable independent shop or dealer could drill that out without pulling the head...
That happened on my Dyna. With the Jim's tool, I got it drilled out, but I could have done it better. Ended up having to helicoil it.
If you're willing to suffer the consequences of doing it wrong, I say buy the guide and take it slow. Otherwise the suggestion of taking it to a professional is the best advice.
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Dreaded Broken Exhaust Stud
