Twister Hammerhead broken exhaust stud...any ideas?

Posts: 5 · Joined: 03 Apr 2007 Posts: 5 Pictures: 0

During our last riding session I notice that the buggy started sounding like it had an exhaust leak. The exhaust nut has fallen off before so I assumed that was the problem but no such luck. The stud sheared off about 1/4 out of the head.

sigh...

I tried using an easyout in combination with lots of swear words but again no luck.

sigh again...

So, any ideas? Do I have to pull the head? If so, do I have to pull the engine? any advice / warnings about pulling the head?

thanks,
g

p.s. If I do have to pull the head any recommendations on upgrades or mods while I have it off?

g

Posts: 529

If there is any stud left to grab onto I use a propane torch to heat the aluminum and then use some vise grips to grab and loosen the stud. Works for me every time.

I had a similar problem with my buggy, the nuts that hold the exhaust on (at the head) kept coming loose and actually falling off. This must have happened at least three times. Even with the bigger studs it happened. Finally figured out that the holes in the exhaust pipe were too big and when the pipe would move it would cause the exhaust stud nuts to loosen. I made some very thin walled stainless steel bushings for the exhaust pipe flange and haven't had a problem since. Now if I could only keep that muffler bracket from breaking for the 3rd time I'd be happy.

SP

Posts: 1916

Download the service manual from SpiderboxPerformance.com

You should remove the passenger seat to make access easier, but you will not have to pull the engine. Since you will have the head off the motor, this will be a good time to polish the ports and replace the cam with a performance version that will either favor horsepower A8 or torque A12.

Posts: 303

Consider yourself lucky. My head had a stripped spark plug hole. So I bought a new head and broke the stud while putting it in the new head, ouch! I ended up re-drilling and tapping a new hole, couldn't stand the thought of buying two heads, and 20 bucks away from a big bore kit.

Greg

Posts: 343

If u don't have much stud to grab on ,I have welded nuts on what evers left and just unscrewed it.I agree since u have the head off add a performace cam and clean up the head,port and polish.

Posts: 417

Try an easy out with the head hot...try not to heat up the exhaust stud. Propane torch like someone else mentioned should work.

Posts: 2589

This post is perfect timing...

ACBlind busted one of his exhaust studs. We haven't had a chance to fix it yet and he was wondering how to go about it...

Now that we have a welder, all options are available to us...

Thanks guys...

Hey, tr4boy, let us know which method/how you were able to get the stud out.

Posts: 6294

This happened to me a while back. Take a cut-off wheel and cut down into the center of the broken bolt. It will cut a little into the engine, but no big deal. Now get your straight slot screwdriver and back it out. No problem. Very Happy

Posts: 67

I did this on one of my old motorcycles changing the oil filter tried a easy out"helicoil"and then snapped the easy out off in the already broken screw!I was screwed,took it to a bike shop and he used a thin pointed dental looking pick and slowly tapped counter clockwise and was able to get it out thank god be carefulll of easy outs i almost trashed the block