damn it...broken exhaust stud

[buellmekg]

Not looking to start another broken exhaust stud thread. Just wanted to gripe because I'm having to rotate the engine again this year. I know most of my options for removing the stud, still finalizing which direction I'm going to go on that. My question is do you guys recommend any other repair/upgrades while I'm at it. (front and rear head gaskets have already been upgraded)

 

[seancrete]

Weld on a front O2 bung. Polish/clean the header. Check the position and condition of your transmission vent tube (so you don't burn a hole in it when it touches the header). Maybe even reroute it to the left side of the rear cylinder.

Yup, I just did this same repair a couple weeks ago...

 

[buellmekg]

Still havent gotten around to this yet. how did you remove your broken stud?

 

[Chicknstripn]

Easy out or extractor. Don't be ham fristed. Take your time and start with the smallest drill bit possible. Use lub and go a little at a time until you have a depth that is about an 1/8 of an inch or so. Step up the hole size for the extractor/easy out. I usually hold my easy out with a vise grip and tap it with a hammer as I try to get the thing to grab.
Wouldn't hurt to soak the stud in some sort of penetrating oil before trying to extract it.
If it's a good clean brake you could also try soaking it with penetrating and using a center punch. Position the center punch on the outside edge of the stud(what's left of it) and try tapping it counter clockwise. This have worked for me on bolts that have snapped flush on automotive brake rotors.
Here's an old thread on the topic of exhaust stud removal. There are a ton of them out there.
http://www.badweatherbikers.com/buell/messages/142838/634269.html
BTW with head is it? You might need to remove the head to repair it.

 

[buellmekg]

Its the front head. I was planning on rotating the engine, removing the headers trying and probably failling to get the bolt out from that position. When that doesnt work I've already mentally prepared myself for removing the heads.