Hi all,

This is my first post so I'll start on a positive; I'm Chris, from Stevenage, Herts. Been riding for several years, had multiple bikes (Bandits, Fazer, SV1000s, CBRs) I currently own a CBR600 FS that has been my favourite (and owned the longest too) picture below



and also a picture with my daily work hack, 1999 GSX600f



and there they are together, isn't that nice ...



Any way, had it for just over a year, and it just scrapped through it's MOT last month with a slightly blowing centre box, so bought a new Delkevic downpipe and collector set to compliment my Delkevic back box, I'm no mechanic but can do routine stuff / minor servicing etc and though how hard can removing eight studs be .... well it all started fine, first two came out with no issue at all, basically i snapped off all remaining six

And the FS is looking pretty sorry for itself.



Tried literally everything, soaking in WD40, heating up, shock and unlock (freezing spray), dremeled, we've worn out stud extractors, my Dad thinks they are hardened steel studs so we've got two hopes drilling them out in situ, before I embark on being raped by my local motorcycle mechanic are there any other options, I have a feeling the engine needs to come out (been quoted 10 hours work for a remove/refit when head is drilled out or replaced)

Thanks for your time!

Kind regards

Chris

 

Maybe weld a couple nuts onto the studs, then try heating the aluminum again, while wrenching on the nuts you welded on. Or if there is enough stud, twist on two nuts on on stud. Tightened against each other and wrench on the inner one while aluminum is hot. You could drill them out yourself, if you had a short drill, if theres not enough room to get a regular drill in there. And if not you could remove the forks to make more room. Left handed drill bits might help. If you could get nuts on remaining studs, try tapping on the with a hammer, not hard, just over and over, a bunch of light taps. That might help break the loose.

 

This is a good idea. The welding alone will heat the steel up and as it cools, the nut should make it easy to turn (anyone ever run a bead on a bearing race to get it out?).

Lots of penetrating oil first.

 

Believe me, I've used more penetrating oil than a Nuru Masseuse on these studs lol! Good shout on the stud weld, will see if I can give that a go!

Thanks for your help

#keepitupright

 

Update? I'd be interested to know what worked best for you.

 

I'm wondering if you could get some liquid nitrogen on the stud, then shoot more penetrating oil in the microscopic gaps created.

 

Ah yes, been meaning to update. Thankfully my brother in law came to rescue and persisted with drilling them out, several hours and £150 later he done it

He also fitted my down pipes too!



Click for vid

obviously had to test her out again



Happy days

 

Very nice

 

hello and welcome, looking good, glad your sorted

 

Jims Tools makes a jig for Harley exhaust stud drilling. So long as you have one decent stud it slides into the exhaust port, is held on by a single nut on the good stud, and has a hardened sleeve that a drill bit runs up inside. Seems like there might be a market for something like that, but of course all HD exhaust ports were the same size for about twenty years so that made it easier to manufacture a single tool at a reasonable price. I don't know how much variation the Honda's have.