Removing head exhaust stud ( pic)

[recumbentsrcool]

The stud on the head broke off coming home from work last week. I ordered a new stud from the dealer and expect it Aug 22. Now, how do i get the old stud out? I stopped by a local scooter shop and they gave me some advice but after looking at my engine, what they said didn't make any sense.

[Lennox]

heat up the aluminum, and then use vise-grips to get it out.

Sears also sells a "tool" that helps. It looks like a socket, but it has "knife-edges" inside. Slip this over the stud, and remove.....

[speedy_scooter]

Its hard to tell in the picture if there is any of the stud exposed outside of the hole. If there is you can get 2 nuts that are the right thread pitch and lock them down on each other. What I mean by that is put them both on and then tighten them against each other. Then take a box wrench and take a hold of the bottom one and pull it out.

If there isnt any exposed threading left then you can go to a hardware store and get a bolt extractor kit. Sears has them for like $30 but it makes the job super easy. Just get the set that has your bolt thread size in it. You then just read the instructions and pull it right out.


Looks like Lennox beat me to the second way... _o

[recumbentsrcool]

There isn't any exposed threads.Its flush with the head. The scooter shop i stopped at advised going to a machine shop and not to even attempt to mess with it. They did say that removing the head would expose more of the thread, but as you look at it, that doesn't apply to the vino. I heard sorrow broke his head stud as well.
The local yamaha shop is closed on my days off.

[Lennox]

I thought you already had one out, and neede to remove the other......

Goto sears, or any auto parts store, and buy an EZ-out. You can do it yourself.... you do have tools right?

[recumbentsrcool]

I have a ton of tools. Some of them get lost from time to time. I do have a 40 piece tap and die set. Is that the tool your referring to?

[Sorrow]

I had to heat mine up annd use ez outs as well. Comes out in about 3 minutes when applying heat. Will need to take off the brass pipe (oil regulator) in order to get better access. simple to remove and no oil will leak out so no worries. Will need to use the smallest ez out you can. Also using a carbon or titanium bit will help with the predrill hole you will need. When putting in the new stub you want to make sure that you give yourself enough length in order to put the exhaust falnge and a fair amount of threads for the nut. If you only leave a few threads it will break off easier as alot of pressure will be place on the end of the stud instead of having many threds to distribute the vibration and stress the exhaust is placed under. I eventually drilled mine out and put in 8 mm studs.

[recumbentsrcool]

What size ez out did you use? How much bigger are the 8mm studs then stock? I was thinking that you screw the studs in until they are seated tightly. Do i use lock-tite of some sort? Wouldn't using longer studs be a better choice?

[Sorrow]

No longer studs won't work. Will not have enough room to slide the exhaust on. You will see what I mean when you put the pipe on. Blue locktite and sorry forget the size ez out I used. It was small. 8 mm are 2 mm bigger than stock.

[brian1wills]

The trick I used back in the auto shop to remove broken studs was to weld a nut on the end then just turn it out.

Take a nut slightly larger than the stud size, hold it over the broken stud with vise-grip or similar pliers. Then using a wire feed welder start welding the nut onto the broken stud. Welding through the small hole in the nut may not be the easiest thing to do, but the heat from welding also heats up the broken stud. After welding let the weld cool slightly and just spin it out like a bolt. It may take a handfull of nuts and some patients, but it does work. Just make darn sure you weld the nut to the stud and not the area around the stud. You could also take it to a local welding shop and they may be able to help.

Just an idea, maybe it won't work in this situation, maybe it will.

[XPS1210]

You can probably use a small screw drive and get enough of an edge to unscrew it...

I had this happen and mine came out that way... However! The tools from sears work best...

[recumbentsrcool]

I found a shop that will remove the damaged stud for $10 to $30. I might have them switch to the 8mm studs. One shop was saying to use a 6mm hardened stud.
Will i have to enlarge the holes on the exhaust flange for the 8mm studs?
Whats the tq specs for tightening the exhaust flange?