So it finally happened, one of the studs connecting the exhaust to the cylinder head broke. The problem is getting the other half out. Any suggestions other than taking it to the dealer and getting ripped off by a so-so mechanic? We tried using an easy out (bolt extractor), but that broke. How long should I spray this thing with WD-40 before trying to remove it again? Should I be using something other than WD-40 to loosen it up?

 

liberally spray it with PB Blaster( about $6-9 a can), don't keep spraying for a long time tho, and let it sit for a good 3-5 mins and well how is it broken? if it is broken CLEAN OFF i would say to try and grind a notch into it for a screw driver don't worry.. this stuff is NON flammable

 

yeah the bolt is probably heat rusted on there, if the stud is sticking out a little bit i would try some good vise grips, other than that i would try what speedy said.

 

There was a thread on here not to long ago, sounded like the same problem. Try using easy-outs.
Here is a random set found on google Hope this helps.

 

hey if ya can't get it out you could always drill it out and retap it

 

Another option is to carefully tack weld a nut to the stud remnant. This has worked for me in the past.

 

i got a wolverine and had the same problem, except only half of my stud broke and i ground the flange down a bit. That gave me only a couple of threads but it is holding. i went to buy a new stud at the yamaha dealer and they told me there is no real easy way to get it out. because the head is aluminum and the stud is steel, with all the heat the stud is almost stuck in there. They said do not use an easy out because it will most likely break as u have already found out. He did say the best way would be to heat up the aluminum part and try to notch the stud and use a screw driver and hammer to break it loose. its probably pretty hard to get in there though with the motor on the bike,which i found. The only sure way to get it out is to take the head to a machine shop.