Its a nightmare at the minute, squirted some wd40 into the stud threads on the head, the ones that came out with the nuts and some of the alloy threads came out with the wd40, they look a bit crappy on closer inspection. I'm hoping there is enough left to hold the new studs.

 

Update:
7mm nuts arrived today, attached two to each stud and turned them out. Worked great. So fingers crossed once I get a nut welded onto the broken stud it will just turn out.

 

Nice to hear your having some luck and progress

I had a sketchy internal thread too... bought a simple tap and die set, and then cleaned up the threading nicely with the correct metric size tap (can't recall at the moment). Most of the damaged threads in my case were within the first few turns, because it became super-easy to twist it in. This gave me some peace of mind that the stud would hold (and the specified torque on the exhaust mounting nuts was very low anyway.

 

Not having much luck with the stud. Used a 90Amp Mig Welder and it stuck to the nut but just kept breaking off the stud. I have a mechanic friend with a 200amp mig, but he is away until the end of october So looks like the bike is off road for a while.

 

That's a shame mate, I'd be pulling my hair out by now.

Only thing I can suggest with the welding is to get a bigger nut, put a blob of weld on the stud then tap the nut on with a hammer before welding, just to give it more surface area.

 

well first of all that WD40 sucks i could never get it to work for me at all on anything, Try PB Blaster it is way better soak the stud with it a couple of times it has a catalyst in it so give it a couple of hours to seep in everywere then try it again. If not the easy out method seems to work very well so long as you take your time and make a really good center punch to start the drilling.

 

Good news everyone, I got a call yesterday saying he was back for a short time and could sort it for me. He made the removal look easy. Built up the stud with weld and then simply used mole grips. Very slowly moved them up and down, only a few millimeters at first until it broke free. Then he just turned it out like normal. The guys a legend. New studs and nuts now fitted, all exhaust system on. It didn't wanna start though, which I thought was strange. Really struggled, it was like there was no fuel at all. Then a few splutters and it started, but was miss firing and sounded awful. Kept cutting out and eventually run nice. Took it up the street and on acceleration lost power and cut out. Left it running for a while and it seems ok now. Started first time this morning. Need to take it out for a good ride now.

 

Went out for a good ride last night and everything is back to normal. Would just like to say thanks to everyone for the help and advice.

Rob.

 

Good to hear you got it sorted robuk!