While doing routine stuff on the bike today I noticed the rear exhaust bolt on the front jug is broken off at the base (explains the popping yesterday). Nothing to grab on to. Drilled into it with a small bit and tried an easy out. It snapped off and is now filling the hole I drilled. Suddenly all my small bits are dull (must be the weather) . Rather than beat a dead horse today I'm going to contemplate it and decide what course of attack would be right. A couple stiff drinks for intellectual fortification or forgo that and get another set of small good bits plus an easy out (today is a no go as I'm watching the grandson). Any suggestions? Looked in past posts and they deal with something above the surface that can be readily gotten to. Thanks.

GP

THERE IS NO SUCH THING AS AN "EASY OUT"! They are "screw extractors" and it is not "EASY"!

Clifford

You might want to invest in a drill bit sharpener. Those easy outs are hard as H&ll. I feel for you, Take your time and be sure you don't drill to one side.
Might be quicker just to replace if the easy out is deep.Have you tried a small punch,sometimes you get lucky and can work it loose...Good luck

THERE IS NO SUCH THING AS AN "EASY OUT"! They are "screw extractors" and it is not "EASY"!

Clifford

Ok. Never had to deal with them much in the past. Threads on the stud going into the head are left or right handed (not that it matters at this moment)? Assuming left.

GP

I'd actually assume right hand thread. Never seen a left hand threaded exhaust stud before. Have you tried heating up the area around the stud to see if that will help to loosen it up? Then take the hammer and punch and try to spin it out.

Fun , fun , fun! Listen , you will need to bust the tip of that easy out - out with a small punch. It'll work , I've had to do it a time or 3 myself. But they are hardened steel , so you will need to really give it a whack. Once the E/O is out of the way , clean the hole back up where you can work with a fresh Extractor. Use heat if needed around the bolt(to make the head expand , not the bolt).

Question , do you weld? I do. Here is how I removed several exhaust bolts that were broke off flush with the head on my Cadillac 500 motor. Weld just a little on the end of the broken bolt. Then put a nut around that weld and weld the nut to it. Presto , something you can stick a wrench on again. Maybe someone in your area that welds could help , if you don't.

Hope this helps , and BTW , they should be RHT as Jamie mentioned. BB

Unfortunately not a welder nor have one. Figuring if I can get a small bit in there close enough to the tip of the extractor I should be able to pop it out. Then I can, hopefully, get some leverage. In the meantime, back to pondering and hoping they didn't use red loctite on this too. Thanks BB.

GP

Jamie's right, use heat. Go to Harbor Freight & buy a SMALL butane/ propane torch. The smallest they sell. Warm the aluminum, it will expand faster than the steel. Witha new/sharp screw extractor, it should come out

Gonna call it a day. Sleep on it and try again Tuesday with a fresh perspective (and better tools). Dawned on me that if I could get a groove cut in (what's left of) the bolt with a Dremel I could try a flat bladed screwdriver to work it out. It's pretty chewed up right now and any more attempts will worsen the situation (I'll probably end up drilling out the bolt and re-tapping the hole). BTW, anyone know how deep/long the hole/bolt is? I'll get a small sharp drill bit and extractor from one of the maintenance guys tomorrow and go from there. Thanks for all the input guys! Gotta go play with my Grandson.

GP

GP go buy a replacement stud first. That will tell you which way the threads are going and you will need a new one anyway. It will also give you some idea of how deep the stud goes. You can also double nut the remining stud and pull it out to see how deep the hole is. Good luck on your task.