Twisted exaust stud in half

[2001Toomey]

Well, we had a rattle coming from somewhere on our 400ex, and we had the hardest time trying to find it. The other day I was just cruising and I bend over to look while riding and I spot the exaust collar thing is loose. You know the collar that goes around the header to keep the header tight to the head. Well so we try tightening the nuts, nothing, probably rusted tight. So we try loosening um too. Well of course they start to move, and finnaly just the nut and tip of the stud just twist right off.

What is the reccomended procedure for backing out that broken, and probably extrememly rusted stud? :eek2: And what caused the collar to get loose if the nuts were night? Is this one of those stud pulling out like on the head type deals?

For extraction should the head be taken off to work on, or just leave it on and try and take it off from there? We're thinking of stripping the bike down and sending it to the dealer to do. By stripping it we'd save them the hours ($$$ for us), and we don't have the experiance to be messing with the expensive parts like the head. How hard is it to take the head completely off of the motor?
Thanks.

[ss440ex]

Find a nut that will slip over the broken stud,
have it welded on and unwind it out.
Maybe use some penetrate spray.
Good luck.
This will usally work.

[2001Toomey]

Thanks, that sounds like an easy way. :blah:

[2001Toomey]

Hold on though, should the head be taken off for this, or just remove the oil tank and plastics and all that?

[aviator4]

If you can get in there without taking the head off, then give it a try.

I know on my 400 I wold have to remove the head to get a broken stud out. I recently did the same thing on my wife's 250EX. I had to remove the head to get it out.

I tried the weld-the-nut-to-it trick, but just twisted off more of the stud. Finally, I had to drill the stuf and use a GOOD QUALITY easy-out to get it out of there. The one I used was out of a set that cost about $300 from SpanOn.

If it's completley ceased and nothing works, take it to a machine shop to have it removed. Don't risk screwing your head up!!!! It's cheap to have this done. I think like $20-$40 or so.... money well spent.

Also, when you re-install it, use a NEW gasket. These are "crush" gaskets... they are ONE TIME USE ONLY. It's not worth destroying your engine for something as cheap as a gasket. and torqe the bolts to spec!

[2001Toomey]

Thanks guys, it should be said and done by the end of the week. :cool:

[reichart90]

hey dude. i did the same thing a couple weeks ago... i used one of those stud extractor sockets. worked like a champ. works good for installing the new ones too so they're good and tight! you can probably pick one up at your local autozone or similiar place or if you are friends with someone that has a garage of any sort. basically the socket has some sort of rollers or bearings in it. i didnt really look at it close. but id say give it a shot. worked for me.

i always go over most of the fasteners on my quad before taking her out riding. all that beating they take and heating up/ cooling down... it loosens a lot of stuff up. i always feel better too when i know i checked everything out. i sure as hell wouldnt want to fly off a trail from a wheel flying off!