Yamaha TRX850 Enthusiasts Forum

damm and words to that effect just snapped exhaust stud trying to take downpipes off looks like its been bodged before about 3mm stuck out of block any ideas block around tread is damaged by chisel not me so looks like previous owner has had a problem and i have inherited it cheers

Stud extractor I would say but with plenty of localised heat to it first.

this is going to be very tricky and unless you are confident dont do it !!!
you can try the stud extractor i have found that they are not to good in this sort of job ,if it were me , and it has been (Ive done a few ) i would drill it out, start off small about 2mm and try to get this in the middle of the end of the bolt if it is not flat you will struggle so make it so,once youve done the 2mm move up in size take note how far off center you are and with the next size drill say 3mm make the adjustment to get you on track until you are at the right size then put a tap down the hole ,remember not to deep or your f@@ked i think its 8mm stud so you will need a 6.8mm drill, TAKE YOUR TIME !!! if this is to scary,, head off ,and down to the engineering shop were they can clamp the head and do it as above hope this helps

No real tips mate, other than take it to someone that knows what they're on about but remember, the stud screws into the barrel so you DON'T want to damage the tread in the barrel: trying to drill it out yourself especially if the engine is still in the bike and you're laying on the garage floor to do it is well risky!

Get a washer that fits over the broken stud (nice big OD but tight ID to the stud).

Bluetack the washer in place so it doesn't fall. Then weld a suitably big bolt onto the broken stud by welding into the thread area. The washer will prevent weld getting onto the engine cases.

After the bolt is welded in place, undo it before it gets cold as the heat generated by the weld will help you undo it. The bigger the bolt the more leverage you will have on the stud.


Forget easy outs or drilling until you have tried this. Its by far the quickest way to remove these damn studs.

If im correct in asuming the stud is 3mm proud of the head your better off welding a washer to the stud then weld a nut to the washer and unscrew while hot. Good luck.

I think I'd go the Sp!ke route or something similar. If you don't weld, take it to someone that does. And don't use acetalyne!

Oh, and I think I've broken more "easy" outs than studs...

dilthedog have you got a welder ? and can you weld? this may be your best bet if so ,, it sounds a good idea

i have drilled it out a friend who works for westland helicopters is coming around to re tap the thread then make up a new stud thanks for all your advice some good tips cheers

well done dillthedog !!!!!!!!