I broke the stud on a 99 tc88 bagger in the rear cylinder, right side. Any tips on tools or suggestions to get it out without ripping the head off? The rest of the studs are really rusted and will probably have the same problem if I force them...any past experiance????

Joe

 

Be sure to drill dead centerin the stud thats left all the way through to the other end....this will relieve the tension if the bolt and with a good easy out you should be able to extrast it fairly easy. Not be afafraid to use a little heat and wd40 and some few chioce words.

 

You must be perfectly centered and maintain center if you drill it out, otherwise you ruin the head. J&P Cycles has asimple jig that it keeps the bit centered. My brothers broke off and he took it to our local indy and he had it drilled and restuded in 15-20 minutes. Probably any Indy, or dealer for that matter has the jig asthis is a common occurence. I would spray the other studs with a rust buster and let it set overnight before attempting to remove the other bolts.

 

If part of the stud is still accesable, i have used and assenmacher stud puller with great succes.
If not, Doc and 2k got it right...

http://www.asttool.com/search_result...=stud%20puller

 

left hand drill bits ,and no this is not a joke,predrill with a small pilot bit like 2kflhr said ,spray it down good with some type of penetrant then use a left handed bit ,it will catch and back the broken stud out (most of the time)

 

If it is broken off flush, a good welder can tack a bolt onto the end and screw it out. This is the easiest of all methods.