how to remove a broken off screw in exhaust end cap?

[nevadatrx400ex]

was wanting to take out the spark arrestor to clean and inspect and while removing screws on exhaust end cap, one of the screws broke off flush. whats the best way to remove it without messing up the female threads on muffler?

[nj1978]

this might work for you.i had all my screws stripped in my carb so i sharpened a flat screwdriver on my grinder, wacked it a few times and made a new slot.jsut a suggestion

[tri5ron]

can you post a pic of it?

[powermadd400ex]

mine did the same, get a really small drillbit and drill it out. careful not to hurt the threads on the exhaust. pretty simple.

[Jkeith0004]

subscribed....this happened to me too :o

[bigbad400]

i would just drill it with a size smaller than the threads and re tap it out or just a small hole and try to ez out it but dont break the ez out you cant drill into that hardened steel with a cobalt bit. or you could just run it with 2 its the exhaust for god sakes.

[Ryanwolfe911]

Left hadn drill bit, right down the center. DOes the trick every time.

[mcgrath]

You havent heard the best trick of all. Set a small nut on the broken screw end weld inside the nut to the screw and turn the nut and screw comes right out. Done it a hundred times works like a charm.

[buck440]

easy out:rolleyes:

[GMC400ex]

i had same thing happen to me on my warrior and i just drilled right down the middle of it and used an ez-out like others have suggested then retapped and dyed it..works great now..

[Ryanwolfe911]

You dyed it? What color? lol

[white tails]

my friends did the same thing. That redneck just tac welded it four or five times around the baffel. lol

[Pabst_Powered]

Originally posted by buck440
easy out:rolleyes: agreed, easy outs work wonders, and always nice to have

[nevadatrx400ex]

well, learned a lesson, started to drill it out and then put a easy out on it and was starting to back the screw out when the easy out snapped off,,,,also flush......#$$%$ tried drilling that out too but they are harden metal and it wasnt going so well, so I said the heck with it and rotated the cap and drilled 3 self tapping screws in and it seems to be good and secure so problem solved in my book..........in retrospect I should have continued drilling out the screw and if it ruin the threads, should have re tapped them and called it good.... live and learn.

[81-Honda-04]

Originally posted by powermadd400ex
mine did the same, get a really small drillbit and drill it out. careful not to hurt the threads on the exhaust. pretty simple.

x2, works great

[nevadatrx400ex]

found a nice fella on craigslist who took his stock pipe off to install a better system and will give me his stock exhaust can.

[hack]

dont go cheap on easy-outs though. i bought some from harbor freight and had the EXACT same thing happen to me. harbor freights easy-outs ended up snapping off inside the exhaust.