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Broken exhaust stud

2.4K views 8 replies 7 participants last post by  skidmarc  
#1 ·
Just wanted to share the state of my 09. Since I've owned the bike this is the second time my header nuts have come loose. Except this time the stud broke off. The harley dealer says all the gaskets and o rings are in stock but if they can't drill out the stud then I'm SOL. I'm considering taking the bike to a well known engine shop called Hillside motorcycles and machine in upstate NY.
 

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#3 ·
I had a friend with a Softail Deluxe who was getting V & H long shots put on at a HD dealer. This is what happened to them when they removed the old exhaust., They ended up having to take the head off to get that out. At least consult the machine shop to review there plan of action before making your mind up. I dont think drilling it out is an option as EZ Outs are not going to budge that
 
#5 ·
Wow is this ever timely.

I refitted my Bassani earlier this summer because it looked like the previous owner didn't know how to install an exhaust (spoiler alert: I've done more than a few exhausts in my years). Two weekends ago the forward header came completely detached and the aft flange wasn't far behind. Besides losing both fasteners, she completely spit the forward gasket out. Thank God it didn't shear a stud, however the silencer did chew the sh#t out of my swingarm. Pissed. Next time I'm using locking hardware.

So sorry to hear what happened to your bike. Hopefully the broken piece comes out without too much drama.
 
#7 ·
Check this thread, it might be helpful


the jig that Phaedrus mentioned is linked there
Regards
Roy
 
#9 ·
I've seen more and youtube mechanics (take it for what it's worth) welding a nut on broken exhaust manifold studs on vehicles and turning them right out. Even aluminum heads. If I were to bust one of these fellas, I'd pick up a cheap MIG and give it a shot... (I've done the drilling and easy-out thing in the distant past and just for me, I am far too clumsy or unskilled for detailed work like that).