Magician exhaust plate stud broke off and pipe broken from frame

[pcast01]

Hello all!

I have been having a blast riding my Magician out and about but I have an issue now and am trying to fix it.
https://photos.app.goo.gl/LYAor5w0cS78MTg22
https://photos.app.goo.gl/ggUb9jSddkfCpus96

So I am thinking of drilling and then what would I used to extract it, a screw or something like that. I noticed the thread http://chinariders.net/showthread.php?t=20141&highlight=exhaust+bolt+broke about it but am not sure exactly what will work.

My other problem is the exhaust pipe broke off the frame, is this safe to leave or should I get it welded back on? Or maybe any other suggestions?

[Weldangrind]

Since you said "get it welded back on", I presume you don't have a welder; that precludes the method of welding a nut onto the broken stud.


If you decide to drill the broken stud out, find a quality industrial tool shop that sells good quality drill bits (like cobalt) as well as left hand drill bits (not joking). Select a size that is roughly half the diameter of the stud. The idea is to use a center punch to locate the middle of the stud, drill into the stud (slowly) and then drill into it again (even more slowly) with a slightly larger left hand drill bit (this time with the drill in reverse).


If everything goes your way, the left hand drill bit will catch on the stud as it removes material, causing the broken stud to spin right out. It's magic when it works properly. I stay away from extractors and easy-outs, because I've broken more than I've been successful with. Left hand drill bits have been very successful for me. It's a good idea to extract the other stud and measure the hole depth, so you don't drill too deeply.


Rather than welding the tab back onto the stock exhaust, perhaps the eBay exhaust that several members have installed on Hawks would work on your bike. Somebody smarter than me needs to chime in there.

[pcast01]

Since you said "get it welded back on", I presume you don't have a welder; that precludes the method of welding a nut onto the broken stud.


If you decide to drill the broken stud out, find a quality industrial tool shop that sells good quality drill bits (like cobalt) as well as left hand drill bits (not joking). Select a size that is roughly half the diameter of the stud. The idea is to use a center punch to locate the middle of the stud, drill into the stud (slowly) and then drill into it again (even more slowly) with a slightly larger left hand drill bit (this time with the drill in reverse).


If everything goes your way, the left hand drill bit will catch on the stud as it removes material, causing the broken stud to spin right out. It's magic when it works properly. I stay away from extractors and easy-outs, because I've broken more than I've been successful with. Left hand drill bits have been very successful for me. It's a good idea to extract the other stud and measure the hole depth, so you don't drill too deeply.


Rather than welding the tab back onto the stock exhaust, perhaps the eBay exhaust that several members have installed on Hawks would work on your bike. Somebody smarter than me needs to chime in there.

Thanks Weldangrind for the info! I was going to go the extractor route but this way seems better. So the size of the stud is 10mm so use a regular drill bit(what type of bit?) that is half the size. Then use a left-hand drill bit slightly larger than the half size and drill in reverse? Correct?

I will have to research that exhaust for the Magician unless like you said someone might know.

[Weldangrind]

You have the process exactly right. Ask for the best quality bit for drilling steel; I suspect they'll offer a cobalt bit.


I think this is the exhaust that Hawk owners are using, but I'm not sure: https://www.ebay.com/itm/Aluminum-Exhaust-Muffler-Spark-Arrestor-Bk-Fits-Honda-Crf150f-Crf-230f-03-16-New/263639704163?hash=item3d6226a263:g:81IAAOSwvyNa4sl 1&vxp=mtr

[Sullybiker]

I've had a lot of luck with reverse drill bits. Just take your time. You might also want to spray some penetrating lubricant in there and let it soak for a bit. Anything to help turn the threads.

[Megadan]

I have seen one Magician using the same eBay CRF230 exhaust that us Hawk owners use. While it does fit, I do believe it has to be modified a bit for the muffler to work, and you can tell by looking that it isn't really meant for the bike. It's a little on the long side.

There are a couple of exhausts made for the Magician style bikes that can be found on TaoBao. This OTOM exhaust is one, and comes with a removable silencer.
http://www.engtaobao.com/item/taobao/547695211685.html

[pcast01]

It's looks like I won't be getting the stud out after all... Where can I get a new Cylinder Head for my magician 250?

[zippy]

I have a Hawk and also faced the problem of a broken off exhaust stud. I took the engine out of the frame and tried to remove the remaining stud and that one also wrung off. Rather than extract the broken pieces still in the cylinder head I drilled and tapped new holes beside the old stud locations. There is enough room for them. A machine shop I consulted recommended I drill the new holes to a depth 1.5 times the diameter of the replacement studs. I did and the new studs are still holding fine after several months. So, you may be able to use your head (the one you've already got) to hold your Magician together.

[JerryHawk250]

It's looks like I won't be getting the stud out after all... Where can I get a new Cylinder Head for my magician 250?
You could drill it out and tap to put a slightly larger stud. Auto part store should carry a repair stud with a larger base thread.
https://images.oreillyauto.com/parts/img/medium/dag/675-097-007.jpg

[zippy]

This shows how I used my head I already had. The newspaper kept the metal shavings out of the cylinder head while work was in progress:

[Weldangrind]

It's looks like I won't be getting the stud out after all... Where can I get a new Cylinder Head for my magician 250?

It's not the cylinder head, but the cylinder. Assuming your bike has a CG250 motor, here's a kit: https://www.ebay.com/itm/ROKETA-ZONGSHEN-CHINESE-250CC-ATV-AIR-COOLED-167FMM-CG250-CYLINDER-ENGINE-KIT/370937489650?epid=688976270&hash=item565d98e8f2:g:yr8AAOSwhOVXdxaQ:sc:USPSPrio rity!98295!US!-1

[JerryHawk250]

It's not the cylinder head, but the cylinder. Assuming your bike has a CG250 motor, here's a kit: https://www.ebay.com/itm/ROKETA-ZONGSHEN-CHINESE-250CC-ATV-AIR-COOLED-167FMM-CG250-CYLINDER-ENGINE-KIT/370937489650?epid=688976270&hash=item565d98e8f2:g:yr8AAOSwhOVXdxaQ:sc:USPSPrio rity!98295!US!-1

??? what you been smoking? :hehe: That's the cylinder head.

[pcast01]

You could drill it out and tap to put a slightly larger stud. Auto part store should carry a repair stud with a larger base thread.
https://images.oreillyauto.com/parts/img/medium/dag/675-097-007.jpg

Thanks JerryHawk for the idea! I will try to get the other stud out with some vice grips and take that to Autozone to get another one with the larger base stud for the other one. What size stud should I be looking to get?

[JerryHawk250]

Thanks JerryHawk for the idea! I will try to get the other stud out with some vice grips and take that to Autozone to get another one with the larger base stud for the other one. What size stud should I be looking to get?

Check see what the auto parts has available and go from there. It won't matter if it's SAE or metric as long as you can get her up and running. :tup:

[Megadan]

Just going to make this suggestion, but if you take the head in to a local machine shop, they can probably extract that stud without damaging the threads for a relatively small fee.

Worst case scenario, order a replacement head through CSC for the TT250. The only real difference will be that you need to make a block off plate for the air injection port on the exhaust side. $85 for a complete head already painted black and ready to go.

[pcast01]

Just going to make this suggestion, but if you take the head in to a local machine shop, they can probably extract that stud without damaging the threads for a relatively small fee.

Worst case scenario, order a replacement head through CSC for the TT250. The only real difference will be that you need to make a block off plate for the air injection port on the exhaust side. $85 for a complete head already painted black and ready to go.

Just curious but how hard is it to remove just the head??

[Megadan]

The head comes off the engine rather easily. remove the valve cover. remove the 3 bolts that hold on the rocker assembly, remove the push rods, remove the 4 nuts that hold the head to the cylinder. remove head. Just make sure to set the engine at TDC on the compression stroke before you begin, this will ensure you are not fighting the valve springs when removing or installing any of the components.

Now, if it can be removed from the engine while installed in the frame of the Magician is a question I can't answer. It can be pulled from the Hawk, and most likely it can be done with the Magician too, but I have no first hand experience.

[Weldangrind]

??? what you been smoking? :hehe: That's the cylinder head.

I have no excuse for that; not sure what I was thinking. :hmm::shrug::crazy:

[pcast01]

This shows how I used my head I already had. The newspaper kept the metal shavings out of the cylinder head while work was in progress:

So my newest update, I had a good friend come over and help me try to remove the stud and we first tried to remove the other stud to see how far we needed to drill but it broke off almost immediately. So we tried to remove that one and no luck. So I am looking at doing what you did zippy.

A machine shop I consulted recommended I drill the new holes to a depth 1.5 times the diameter of the replacement studs.together.

How far did you say to drill? 1.5 times the diameter??

[zippy]

That's right. The machine shop guy said standard practice is to go to a depth 1.5 times the diameter of the replacement stud. I did and the depth of the metal in the head was sufficient to take it.

Good luck. It was tricky to drill the holes perpendicular to the face but I got them close enough to work.