snapped exhaust stud
 

Hi Guys,

The exhaust on the 888 is now off (probably for the first time in 12 years) but despite a weeks worth of soaking with penetrating fluid I still managed to snap one of the suds on the horizontal cylinder. I've got about 5mm of the stud sticking up to attack and would appreciate advice re the best way of trying to shift it (please don't suggest trying to drill it out as experience has shown I'm c**p at doing that!). Anything that avoids having to helicoil it would be great. Would welding a nut to what is left be a good idea ie would the heat help loosen it?

Thanks,

Keith

Welding a nut to it sounds good and yes the heat would probably help in loosening the stud . Good luck

nut is good idea...

had lots of success using a spark aroder in simalar situations.
access needs to be good or take head off..

try local engineering firms or get it to me...
top bit kit which will arode straight in and is not affected by metal hardness..

would use a hex head bit - arode in 10 mm and just unscrew broken stud out...

pm me if you need to..;)

Thanks guys. I'll give the nut idea a go next week and see if I can avoid having to pull the head.

Keith

I want my 888 system polished over the winter and im bricking it at the thought of taking it off for this exact reason..good luck !

Nat

mole grips

In hindsight I should have used a cutting disc on a dremel to part cut through the nuts. I did this on one of the other nasty looking nuts and the nut spun off after a few knocks with the cold chisel without hardly marking the stud. I'm not sure there is room for a nut splitter unless you can get mini versions. I hope the shiny pipes will be worth the hassle...

Keith

I've just managed to shift the blasted stud. The stud was in VERY tight. I kept failing to get a strong enough weld to a nut. In the end I built up the stud with weld until it was glowing nicely then clamped it with the Mole grips.

Keith

Keith... if it ain't broke , don't fix it.
What you up to with it anyhow?
Andy

Hi Andy, The 888 is stripped for a full checkover (I always like to do this with a 'new' bike). The exhaust looked so scabby that it seemed a shame not to take it off and give it a polish. Basically, us 'classic' owners spend our Winters getting cold in the garage rather than getting cold riding :D

Who knows I might even make one of your rideouts next year if I can work out how to put it all back together!

Keith