Remove a Frozen Broken Exhaust Stud on a motorcycle

To remove a Frozen Broken Exhaust Stud on an old motorcycle can be challenging to say the least. I'll show you the hack I use to get this one out of a 1972 Honda CL350 twin without taking the engine out of the bike. It's a tough one, cause it's really stuck.
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Honda fuel petcock fits CB450K 1968-1974 1968 CB350, 1970-1972 CB350K, 1973 CB350G, 1974 CB360, 1974 CB360G, 1975-1976 CB360T, 1966 CB450, 1970-1971 CL175K, 1968 CL350, 1970-1973 CL350K, 1974 CL360, 1975 CL360K, 1967 CL450, 1969-1974 CL450K, 1970 SL350, 1971-1972 SL350K amzn.to/2EPxGOZ
#motorcyclerepair #hondamotorcycles #exhaust

[@johnnon6583]

Man the feeling when that bolt started to turn must’ve been euphoric!

[@Amotorcyclenut]

You know it!

[@mewwew411]

these damn exhaust studs man

[@jabbasan12]

Thank you for posting this video. I was able to remove a broken stud from my motorcycle using this technique. Thanks again.

[@motorcyclerefurbishment8162]

New stud with no grease.....creating a stud issue for the future again...

[@Redmenace96]

I use a product called, "anti-seize". Isn't it for studs like this?

[@vinced2514]

When he started to put the stud in without any anti-seize I wanted to yell "NOOO"! But I guess if he put's anti-seize on the protruding threads of the stud before he tightens up the nut that holds the exhaust flange on, the stud shouldn't snap off again in the future. I NEVER put a bolt back in without anti-seize (or Loctite), and especially on a motorcycle!

[@fourbyfourer]

I've watched this video a couple times now, and I still get anxious seeing that broken off stud. But it brings me great joy to see you succeed. Great job my friend, you done an awesome job on the removal, and at taking your time planning.

[@Amotorcyclenut]

Thank you, Sometime the art of persistent mechanical persuasion works out and sometimes it doesn't.

[@tonyowen8349]

Thank for the video very helpful . Greetings from anglesey north wales 🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿

[@Amotorcyclenut]

Glad it was helpful!

[@doncoles1778]

Just did a full on custom job on my nightrain and lol last thing to do was my exhaust and snap. U saved the day bro. Thanks

[@Amotorcyclenut]

No problem 👍

[@Amotorcyclenut]

To support this channel check out Amazon through the links below: Here's where to get some of the tools I used it the video Torx Bit Socket Set amzn.to/2tJHaTv 5 piece CENTER DRILL COUNTERSINK Bit Tooling SET amzn.to/2KpyT1l TEKTON Automatic Center Punch amzn.to/2KwR1FX Left Hand Drill Bit Set, 13 Piece SAE (1/16" - 1/4") amzn.to/2Ck8m05 Black Widow MCC-500 Steel Motorcycle Carrier amzn.to/2N9WYHc Honda 1972-2007 CB Headlight Unit 33120-333-670 New OEM amzn.to/2J9U3z0 Motorcycle Spark Plug Wire & Cap 7mm x 24 For 12v Coils Honda CB450 CM450 450 amzn.to/2LmoGQh Metzeler Tire Set - Honda CB450K 70-74 CL450K CB500K - Tires Tubes and Rim Strips amzn.to/2KSaLjM HONDA CB450 CL450 KEYSTER CARB KIT amzn.to/2KQl8EF Honda fuel petcock fits CB450K 1968-1974 1968 CB350, 1970-1972 CB350K, 1973 CB350G, 1974 CB360, 1974 CB360G, 1975-1976 CB360T, 1966 CB450, 1970-1971 CL175K, 1968 CL350, 1970-1973 CL350K, 1974 CL360, 1975 CL360K, 1967 CL450, 1969-1974 CL450K, 1970 SL350, 1971-1972 SL350K amzn.to/2x9Q9l1 Carburetor Rebuild Kit with Floats - Honda 1970-1973 CB350 CL350 Twins amzn.to/2saGyEX

[@corymckinney3987]

Yeah did that but it fu up and I need it welded up start over

[@AlphaBobFloridaOverlord]

Very nice work and helpful to me! Also, you can soak it with Kroil which is the best penetrating oil I’ve ever used, and sometimes it helps to go tight a little bit before you try to loosen.

[@Redmenace96]

The people tell me about penetrating oil for every stuck bolt/broken stud/stripped head. Years and years. It has never worked once for me!

[@allanbryers4682]

Awesome job sir.. Well done. Given me a new way and inspiration to tackle the same issue. Great calm instruction. Cheers.

[@Amotorcyclenut]

Glad to hear it!

[@Redmenace96]

Great vid. Great angle. The torx head is an idea I'm going to use on a stripped Allen/hex head. Without all the equipment you have, I have used a left hand bit, or an extractor kit to success 2x. They work! Cost money, and you have to give some thought (as you did) to the size and bits, but worth it in the end. Patience is the number one way to remove frozen/broken bolts.

[@mongychops68]

genuine vid, other vids on here are classroom/ text book. this looks real so thanks

[@richardwarner746]

You should try to get a snapped bolt out of a cam bearing cap on the Honda CBX! Had to use an angled drill attachment because of the position of the frame!

[@Amotorcyclenut]

Sounds like that was a tough one. Did you get it out?

[@richardwarner746]

@@Amotorcyclenut yes, thankfully. I can only imagine the damage that could have been caused by a bearing cap rattling around inside! It took about 3 hrs, and a great deal of patience. A mild state of disbelief when it finally came out with no damage to the female threads!

[@snaproll94e]

Nice job and without any of those special mechanic words. What's with the notch at the bottom of the port? Looks like a flat exhaust pipe flange wouldn't seal. Thanks for the video.

[@mikebaird1110]

thanks for the great video , i just broke a stud of from a 1980 suzuki gs1000g . i was not happy , but now im confident to do it myself , Thank you

[@Emory-vs6qt]

Got it thanks so much very informative

[@Amotorcyclenut]

Glad it was helpful!

[@jackweber9535]

Had this happen to both bolts in my bike, absolute nightmare gonna try this when im back from work

[@corymckinney3987]

Lucky man

[@eskertoo]

Great job!

[@harryoldham3358]

This literally happened to me last week, it sure is a bummer lol. Bikes been sat in the garage since.

[@allenc5108]

Great method for the home mechanic. Handy to have a welder. I agree heat is a key element to resolving a broken stud. I think it helps breakup any corrosion between head and stud as well as expand the metals. I would have guessed pounding the torx into the drill hole might tend to expand that part of the broken stud making it stick a little more. But it came out and no damage to the head. Thanks for sharing we are all a little wiser for your efforts.

[@hottfats]

The end music was timed perfectly, felt the relief

[@Curley166]

Thats genius! Have had several similar situations in the past and always paid a welder to get stud out. That torx bit idea is simply genius. I know i will be using the soon, when i replace the exhaust studs on my BMW K75. I have not heard of anyone who has tried it on these bikes ever getting all of them out successfully without breaking a few! Thank you for sharing!

[@oo9467]

Good useful video thanks

[@Amotorcyclenut]

Glad it was helpful!

[@petemoss8625]

oh the joys of exhaust studs, but great vid, I will give it a go.

[@detrimundo]

thank you for a most excellent and informative video....

[@MyDyerMaker]

Might try this method this weekend. Gonna use left handed bits first though. Heat seems to be the trick. I'll use a little propane torch so as not to melt the aluminum, I hope.

[@WorivpuqloDMogh]

Had this happen to my bike... really sucks

[@bluesmaster9896]

anyone else notice the drill rotating ant-clockwise at start?

[@jcwoods2311]

Optical illusion

[@ronnierabell1]

Me too

[@travharrell1713]

This was exactly what I was trying to do. thanks. I'll be trying this this afternoon.

[@firestorm755]

Brilliant and very clear. Thanks.

[@ribbledean4111]

Gonna give this a shot, I got same issue I hope like hell it works for me

[@stacygoff1788]

like the torx idea personally i fine heating the stud doesnt work as well heating the base matl be it alum steel cast iron

[@hunterdupont558]

Can u weld a bolt on to the stuck stud with it on the atv ect without blowing the cdi box or any thing else ?

[@Amotorcyclenut]

It wouldn't hurt to disconnect (unplug) the CDI box, just in case.

[@ryanromero4763]

Can you remove mine?

[@jenniferrafiner933]

Best solution I have seen yet!!

[@mikeshobbiesandrandomstuff]

You sir are a magician.

[@donweaver1600]

Pray the drill don't snap

[@geraldwest3428]

Wow I was excited to see it come out! Excellent job man! And thank you big time for making this available to us. I just discovered this same issue with a sportster I just bought recently.

[@Amotorcyclenut]

Glad you enjoyed it!

[@GARGOLASPERFORMANCECOATINGS]

Nice job !!

[@johnpower8356]

Hack work altho it worked, transfer punch would have put center punch dead on center when you say root size do you mean the minor dia? There are much better ways, you could’ve mounted that ion a Bridgeport table and used a mill tool directly down the center worh no heat or an EDM machine or disintegrator

[@Amotorcyclenut]

Most mechanics don't have a transfer punch, or a Bridgeport or an EDM machine. On top of that you would have to totally remove and disassemble the engine to use a Bridgeport or an EDM machine. If you have that kind of time and money go for it. By the way, I was riding the bike a hour later and you would be ordering gaskets. Root Diameter and minor Diameter are similar.

[@corymckinney3987]

What if you f ed it up now am f ,ked

[@cb400fhonda6]

Most diy folks dont have welders Laying around Sure its gr8 to be able to keep One Some home owners insurance Will not cover your burnt down Home bcz u were wellding The fire dept,the city rules laws Are different all over So keep that in mind May be you want to disclouse That aspect Its very risky All that current and heat ! Never the less Gr8 video Thanks

[@johnhughes7491]

Great job

[@911Blair]

Awesome! Thanks!

[@kiksmotovlog3865]

My yamaha mio i 125s has the same problem.. Mechanic told me i should go to machine shop to fix the problem.. Bolt screw got rusty.

[@simgoldsmith]

Hi.... I have been looking for some advice regarding a stud which is turning itself rather than the nut? It's on a 2016 Sportster with the engine still in so have very limited clearance. Anyone have any suggestion, thanks

[@philmanwarren3666]

where did you get the little torch ?

[@kevinstearns4198]

ebay

[@jorgesantoine24]

Nice video thanks!

[@Amotorcyclenut]

Thank you too!

[@mikepool215]

Made it look so easy.

[@Amotorcyclenut]

Thank you. It's not always easy. Some times it works easier that others. Always room for improvement in how its done on a case by case basis. Having a big bag of tricks in your back pocket helps.

[@simonrusk3338]

Very 👍 well done

[@Amotorcyclenut]

Thanks for the visit

[@ronaldwrencher6879]

I have 93 xjs600 secca 2 with one header with both studs broken but I have no stick welder to complete that process any suggestion?

[@Amotorcyclenut]

You could skip that part but your chances of success might go down depending on how stuck they are. You'll still want to heat with a propane torch.

[@marksnodgrass4728]

draper torx broke on me what now? lol, i heated it about 5 times and would not budge sadly. I can see this would work well but not for my stud unfortunately 😔

[@Amotorcyclenut]

Sorry to hear that. I does take some finesse to get them out.

[@crazytestpilot9434]

Heating the stud itself in theory should actually make it tighter as it expands with heat.. I think you only need to heat the aluminum which will expand faster than steel and release the bolt. I'll bet your lincoln welder loves you, isn't that hard on it?

[@johnlang3233]

in practice the stud will expand then contract & break the seizure - needs care but works.

[@hutch36xx]

Good job !!

[@Amotorcyclenut]

Thanks!

[@arthurleino]

Good video.

[@Amotorcyclenut]

Glad you enjoyed it

[@philspaseo2377]

What are the symptoms that this might happen? Would it not accelerate past 60 mph and make a large sputtering noise past half throttle?

[@Amotorcyclenut]

The stud was missing and there was an exhaust leak there.

[@Crism319]

Thanks

[@Amotorcyclenut]

No problem

[@mikeopenshaw9128]

Great informative video - thank you!

[@ination5910]

Very good excellent, without engine down you can do this job is awesome.

[@Amotorcyclenut]

Thank you very much!

[@megabilky]

Love the welding rod trick and a very interesting clip 👊

[@Amotorcyclenut]

Thank you! Cheers!

[@ashy1423]

Great job😊

[@csiautodetail]

The only problem is I don't own a welding machine

[@Amotorcyclenut]

Just heat it with a propane torch the best you can. Use a sharp drill and you'll be fine.

[@csiautodetail]

@@Amotorcyclenut thank you!

[@markopiovarci3038]

Maybe a silly question but is it safe to use torch there while the engine is still full of petrol?

[@jorgechirinos8986]

Very clear Thank you

[@Amotorcyclenut]

Glad it was helpful!

[@charlesscottkelly]

Nice one.

[@Amotorcyclenut]

Thanks!

[@mckinnleyteague5629]

Always helps to run the drill in forward too.

[@arthurfricchione8119]

New subscriber. Excellent video as a retired aircraft mechanic I’ve never seen it done exactly that way. Do you think just using the MAPP gas without the welder would of worked? Thank you for the video. Artie ❤️ can you apply a small amount of locktite to the stud?

[@Amotorcyclenut]

Maybe. The idea was to get the stud to thermally expand in the hole first, to loosen it. Then expand the aluminum around the stud to get the it loose. It worked. Sometimes corrosion between steel stud and the aluminum head can be a real pain. No need for locktite, because that area gets pretty hot and you might have to change it again in the future for some reason.

[@SrgkillSrgkill]

Can I still make it home with one stud holding my exhaust?

[@Amotorcyclenut]

Maybe. depends how far you have to go.

[@dedexyz8475]

Sure; happened to me this week on my scooter. Cracked it off (my first) because I noticed it was loose- and after barely wrenching- sheared right off. Performance wise....a slight decrease. I can smell exhaust gases, and the mileage is less. After yelling FUCK! at the top of my lungs, gathered my wits- and laptop- and started researching fixes. Will try this approach.