Man, I was just out in the garage fiddling around with my exhaust,tightening things up and I noticed that one of the studs is broken. the bolt is not sticking out, so grabbing the broken part is not an option. I did read threads here regarding this problem and I still am not sure how to approach the problem. I have a can if PB Blaster. Should I use that and get one if those EZ OUT tools from Sears? I recently got a "free" 5 K "service " from the dealer. Figured they couldn't screw up anything just doing that. Well I suppose I'm paying for it now. Should not underestimate those guys! I asked the guy to check the torque on these bolts. I'm thinking he may have just been in a hurry and snapped the damn thing off by overtightening it. Thanks in advance for your help!

 

5K service? are still under warranty?

 

I'll try most things on a bike but that's one I'd leave to a professional. Too damned easy to write-off your head. Take it to a place that specialises in that kind of thing, you really don't want to add to your woes with a broken-off EZ Out tool stuck in the hole.

 

Yes I am but I feel like they are not going cover it because I installed a complete exhaust system myself((RB RACING LSR-1). I will probably call the dealer tomorrow but I will be shocked if they fix it.
Thanks fox and ynots for your thoughts on it.

 

Im just curious... how/why is it easy to fork your head? It seems worst case you would just need to drill it out and re-tap the hole(s) ...? Granted I KNOW its gonna be a pain in the a$$ lmao

There are afew types of extractors and each are said to have their pros/cons.. if it was me I think I would just try a good soak with penetrating oil, give it a pop dead on center with a small punch and start drilling slow with left hand drill bit. Might even take adding a little heat. If this doesn't work you have the hole drilled for the easyout. Patience will be key.

depending on where it broke sometimes its possible to weld a nut to the stud and back it out with a racket.. although on a bike we are talking about some pretty tight spaces.

Done with a welder:
http://youtu.be/SKlYKG2vyaA

http://youtu.be/nIJIVZpZZIw


Slot and screw driver method on a bike:
http://youtu.be/OULe_J7OlmA

 

If you do this kind of thing all the time and are patient then I would repeat what onemindseye said. but it could be tricky if your going at it without experience , those studs are in tight little spots depending which one broke off, and sometimes your tools won't be able to fit due to other engine parts being in the way, you could easily spend three foru hours tring or get lucky - who knows- I would give over to a competent mechanic at HD, at least if they mess it up they are resposible and you will have your ride back in an hour.-> no brainer there.

 

I fix broken bolts all the time.
You need a good punch to center and then a center drill to get you started then use a tap drill one size smaller then the normal tap drill size.
Drill in till you reached the end of the stud. use a good tap and clean it out.
Make sure to use a good cutting fluid for both drilling and tapping.
Just checking the stud that I removed from mine it is a 5/16-24 thread that takes a
letter I (.272) and I would go with a 1/4" drill first then even one size less at Letter "H" (.266) . Blow the chips out.

 

A few weeks ago I was at my Indy's and saw him using this tool (click image):



Jims Exhaust Stud Drill Plate Tools Kit
- designed to guide and keep alignment of the included 1/4" drill bit in order to drill out a broken exhaust stud
- follow up the drilling process with a tap and you are ready to install a new exhaust stud
- CNC machined from BILLET aluminum and anodized to protect the finish
- hardened drill bushing to prevent the drill bit from damaging the main body
- can be used without removing the head on any stud with the proper frame clearance
- instructions included

 

center punch the broken stud and then get yourself a set of left handed drill bits
start small and start drilling since the bolts are only suppose to be 100-120" lbs
they should back right out since the drill bit is turning counter clockwise.

 

Let's see...YOU replaced your own exhaust, but asked the DEALER to check the torque on the bolts? Then "fiddled around, tightening things", afterward? And are blaming the DEALER for stripping the threads? Wow!

If you don't have a torque wrench, you shouldn't have even gone near it, in the first place. Now, have a professional fix what you F'd up, or you could be looking at a much more serious and expensive repair.