200x Exhaust Stud Broke Then...

[Matrix]

Well one of the exhaust studs on the 200x broke off and so I soaked the little guy in PB'Laster and let it sit for some time then tried getting a socket around it and removing it that way.

Well that was stupid because it just rounded the stud (by the way there is no head, just the stud sticking out .25"-.5" from the head). So I soaked a little more in there again and tried some channel locks.

Okay that was stupid because these are not the best to begin with. Now my brother bought some new ones with more aggressive teeth.

Okay, why didnt that work? Maybe I'll just remove the engine and try again. After soaking it with more of the P B'Laster (or what ever it is) I remove the engine and put a tad more there and try again with the channel locks but no luck. So I bought a Tap and Die set and a Easy out by Kobalt. After Filing the bolt straight and more PB Blaster I Center punch my hole and begin drilling with the smallest bit and get progressively larger as I go (no pun intended ). I go in about as far as the stud itself thinking if I drill the length of the Stud maybe it will come out easier. Then with a tad more of the good stuff I insert the Easy out like it calls for and get my crescent wrench to spin it. I am very slowly spining it, about a quater turn. Then when I start spining it softly, it snaps!!

After dealing with a at Lowes I got a new bit (ITS A WARRANTY THING ANYHOW, EVEN ON THE PACKAGE IT SAYS "No questions asked"). What should I do now? I bought a center punch hoping to drill out the center punch but a few taps later it is bent! The new drill bits I bought hardly even scratch the bit either. Im sure it has happened to a lot of you especially that own shops. I really dont want to take the cylinder off either but my friend says he could drill it out at work because he works with presses and what not.

[yamaha driver]

pics are not working

[Matrix]

I was working on them when you were looking at my post. Sorry that they are sideways.

[atc007]

No good answers here,except ,never trust an easy out. They only work 5% of the time,,very slick when they do.. But almost Aways break,leaving you with a MUCH worse situation then you began with. Some machine shops can drill Them out with a very slow speed diamond drill. Sometimes there's enough there to weld bolt too,then back it out. Doesn't look like the case with yours. Sometimes you can drill and play around beside them,,then go bigger when you're done... Not here. I think your only shot here is,,weld a new exhaust stud to that broken mess,or see if a local machine shop can handle the job. Nice 83 R and pussy cats! The R needs a bath!

[threewheelin-feelin]

if theres enough to get a good bite with vise grips try thoughs...i got two of mine out of my 350x head with the tighen loosen method...took about 2 hours of constant back and fourth motion...so make sure you have some one there to talk to you lol...the local machine shop did the other 2...i think they charged $30 a piece...and if i had know that before they would have done all 4 lol

[fabiodriven]

This is a thread we get here every couple weeks Matrix. It's a very common issue and you made all the classic mistakes.

These studs almost always snap. Your first mistake was not heating up the head. Unless I missed it, you never said anywhere that you applied any heat. Mistake #1.

Your second mistake was using an EZ Out. Don't ever use EZ Outs on anything. THEY DO NOT WORK. 007 says they work 5% of the time. I say they work less than that. They absolutely suck.

With heat, luck, PB Blaster, an impact gun, and a lot of restraint on the trigger finger there could have been slight hope of removing the stud initially.

Do yourself a favor and skip the next classic mistake all of the guys make. Do not take the hand-drill to the the stud, for your own sake. The only thing to do at this point is take the head off and put it in a mill.

Do yourself another favor and get yourself some reverse-cut drill bits. That way while you're drilling the stud there is a chance the bit itself will remove it. I own a set and yes, this has worked for me before. You know when you're drilling and the bit catches and brings the drill to a halt? Sometimes if that happens with the drill in reverse, it will back the broken piece right out.

[3Razors]

Stay far away from EZ Outs on exhaust studs! They only work when a broke stud is loose to begin with. Drilling is quite possible. The best little tool I've used for this repair is a Quickcenter. It makes a perfectly centered pilot hole that you gradually drill out larger and larger until you can unwind the remaining threads in a coil or pick them out with no damage to the original threads. Make sure to use nice cobalt drill bits for easier drilling as the exhaust studs become heat hardened from use. Try www.quikcenter.com also there is a vid on youtube that gives a demonstration.

I have been able to grind/drill out busted ez outs without mill use but it is very time consuming. Go down to your local harbor freight and pick up some diamond drill bits and chuck them in a die grinder and go to work. Go very slowly with not too much pressure and let the bit do the work. You will probably go through a 3 or 4 of them depending on how deep the ez out is busted off inside. http://www.harborfreight.com/catalog...mond+drill+bit

[fabiodriven]

^^^Haha^^^

Can you fix that link 3razors? That sounds like an awesome idea but your link is wrong.

[3Razors]

Looks like I misspelled it Fabio. It's www.quikcenter.com They have both metric and sae sizes.

[blue27]

you can try putting a larger nut over it and welding that to whats left of the easy out, but welding to drill bits and easyouts doesnt always work.

[Matrix]

Well thanks for all the input, I really do appreciate it and its a damn good thing I have a forum to go to like this. Fabio mentioned heating up the head? My brother and I thought it would be a bad idea because the head is aluminium right? Or cast aluminium? He and a buddy could do that but could you give me a little insight on how to do it properly so that I dont this lol.

And sorry threewheelin-feelin but I get the terminology swapped all the time on vise grips and channel locks.. I actually tried the back and forth motion for a little while with no luck.

My brother bought me a electric pressure washer for christmas that is to powerful but has plenty of power to push a load of mud off my trikes. The day after I cleaned them, he came over and we went for a ride down the road to my grandmothers but before we did that we spent about 3 minutes in my woods warming them up and mud caked everything. So yea... their dirty 007 lol.

[atc007]

You're gonna get thru this. At least you gave it MORE than a sailors try instead of coming on here and wanting someone else to come fix it for you! I like the Razor idea above. Haven't used them,as I try to avoid these situations nowadays! Good luck,, and let us know how things work out!