Exhaust manifold stud

[walnut11]

I just experienced a rattling noise up front near the exhaust manifold pulled the lower tupperware in front of headers and what do I find but a broken manifold stud on the first cylinder from the front. Broken off flush with block.
Anybody replaced one of these babies or is it off to the dealer??
Any suggestions more than welcome.
David
Stockbridge Mi
99ltc
77R100/7

[dshealey]

I just experienced a rattling noise up front near the exhaust manifold pulled the lower tupperware in front of headers and what do I find but a broken manifold stud on the first cylinder from the front. Broken off flush with block.
Anybody replaced one of these babies or is it off to the dealer??
Any suggestions more than welcome.
David
Stockbridge Mi
99ltc
77R100/7

There have been a couple replaced, using E-Z outs, but at least one that broke off the E-Z out and had a real bear of a time getting the stud out.

I would try a left hand drill first, or the Sears Craftsman screw removers that are basically left hand drills in function.

Whatever you do, try to center any drilling as good as possible, that way if the stud remover does not work you can drill it with a 17/64" drill and use an 8MM X 1.25 tap to re-tap it. (I think it is 8MM, not 10, but measure one to be sure.) Often if you get the drill centered really well, you can then pick at the beginning of the thread left to get the end out, then with needle nose pliers peel out the rest of it.

If you mess it up too much, it is a Heli-Coil job then.

Just checked ETK, it is an 8MM stud, 55 MM long.

[powerman5kw]

Walnut,
I've been down this road before on previous bikes. I think you find the task of drilling very...not fun. If you can back it out the remaining section, great. I suspect not.

I've used a local EDM maching service, often called "broken tap removal" service here in los angeles. Check out his website. http://www.extractit.com
Might give you some idea where to go in you neck of the woods.

As long as the EDM head can reach affected area, the burn away the steel material (remaing threads) and leave the aluminum threads as if nothing was ever there. Works as advertised, I've seen it done....cost 50 bucks to remove brokes studs on Nomad aluminum heads. May have to elevate the bike to get the tool head under bike once the plastic is removed.

Hope this helps.