Exhaust stud broke.......

Sochin · 06-02-2018, 01:49 PM

Well it got caused by the exhaust center bracket welds had broken, causing stress on the header pipe going into the cylinder head. Now I have a exhaust stud with a broken easy out stuck in it, drill bits that won't bite to drill it out. So it looks like I need a complete new head (beggin for port and polish job) AND a new exhaust in the works.

Chinabike · 06-02-2018, 02:45 PM

sorry to hear that. I broke a exhaust stud on my 125cc. I tried to extract it but no luck so i had to replace the head. I ruined the hole trying extract.

Chinabike · 06-02-2018, 02:47 PM

You could try this. But i found it cheaper to just buy a new head.

Megadan · 06-02-2018, 02:51 PM

A skilled machinist with the right equipment could likely still save that head. Might be worth checking into.

Sochin · 06-02-2018, 04:28 PM

My worries is a skilled machinist will rack up beyond $50 quicker than I can say.

Weldangrind · 06-03-2018, 12:44 PM

You might be able to clock the flange a few degrees, and mark and drill two new holes. There is a fair amount of flat machined surface to work with.
Use a new stud as a guide for drilling depth. What have you got to lose?

Sochin · 06-07-2018, 11:30 PM

Whohoo....head from CSC arrives tomorrow.......then DO I have the patience to deck and port the head????

Anybody have the head bolt and rocker bolts torque specs?

2LZ · 06-08-2018, 10:07 AM

On all of my rolling stock, I loosened the exhaust flange, then re-tightened evenly. After a few heat cycles, I do it again. They don't need much torque either. Even is the key.

Weldangrind · 06-08-2018, 10:44 AM

Quote:

Originally Posted by Sochin

Whohoo....head from CSC arrives tomorrow.......then DO I have the patience to deck and port the head????

Anybody have the head bolt and rocker bolts torque specs?

Torque specs: http://die-kleinkraftrad-ig.de/wisse...itungcg125.pdf

06-02-2018, 01:49 PM	#1
Sochin Join Date: Jul 2017 Location: Montucky Posts: 209	Exhaust stud broke....... Well it got caused by the exhaust center bracket welds had broken, causing stress on the header pipe going into the cylinder head. Now I have a exhaust stud with a broken easy out stuck in it, drill bits that won't bite to drill it out. So it looks like I need a complete new head (beggin for port and polish job) AND a new exhaust in the works. __________________ 1991 Kawasaki KLR250
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06-02-2018, 02:51 PM	#4
Megadan Join Date: Apr 2017 Location: Omaha, NE Posts: 8,028	A skilled machinist with the right equipment could likely still save that head. Might be worth checking into. __________________ Hawk Information and Resource guide: http://www.chinariders.net/showthread.php?t=20331 2018 Hawk 250 - Full Mod list here. http://www.chinariders.net/showpost....62&postcount=1 2024 Royal Enfield Shotgun 650 https://chinariders.net/showthread.php?t=34124
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06-02-2018, 04:28 PM	#5
Sochin Join Date: Jul 2017 Location: Montucky Posts: 209	My worries is a skilled machinist will rack up beyond $50 quicker than I can say. __________________ 1991 Kawasaki KLR250
	1

06-03-2018, 12:44 PM	#6
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	You might be able to clock the flange a few degrees, and mark and drill two new holes. There is a fair amount of flat machined surface to work with. Use a new stud as a guide for drilling depth. What have you got to lose? __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
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06-07-2018, 11:30 PM	#7
Sochin Join Date: Jul 2017 Location: Montucky Posts: 209	Whohoo....head from CSC arrives tomorrow.......then DO I have the patience to deck and port the head???? Anybody have the head bolt and rocker bolts torque specs? __________________ 1991 Kawasaki KLR250 Last edited by Sochin; 06-08-2018 at 12:24 AM.
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06-02-2018, 02:45 PM	#2
Chinabike Join Date: Jan 2018 Posts: 361	sorry to hear that. I broke a exhaust stud on my 125cc. I tried to extract it but no luck so i had to replace the head. I ruined the hole trying extract.
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06-02-2018, 02:47 PM	#3
Chinabike Join Date: Jan 2018 Posts: 361	You could try this. But i found it cheaper to just buy a new head.
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06-08-2018, 10:07 AM	#8
2LZ Join Date: Mar 2010 Location: Volcano, Ca Posts: 7,092	On all of my rolling stock, I loosened the exhaust flange, then re-tightened evenly. After a few heat cycles, I do it again. They don't need much torque either. Even is the key. __________________ "Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350
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