Broken exhaust stud


Information and questions on GL1500 Goldwings (1988-2000)
User avatar
agedbikeman
Posts: 138
Joined: Tue Jun 18, 2019 3:41 pm
Location: Bruay la Buissiere, France
Motorcycle: 1995 GL1500 Aspencade with Insta trike
2014 Can-Am Spyder RT(sold, glad to see the back of it)

Broken exhaust stud

Post by agedbikeman »



Further to a previous post "Exhaust, age old problem"
I have now managed to remove the collector box by as you suggest dropping the R/H downpipes, no one said you had to remove the crashbar aswell, anyhow it's off at the expense of a broken stud, see photos.

What are my chances of getting it out, should I,
1. try and take it out with a mulgrip tool
2, leave well alone, and fit new seal rings, bolt it back and hope it doesn't leak, the front pipe is attached to the middle pipe by a steel bar, so it's not as if No.1 pipe is hanging on one bolt, hence why I had to remove the crash bar






Also the ring that I'm pointing to with a wrench is the seal between downpipe and collector, it's firmly stuck but in good condition, I assume i can re use this?

Thanks for any input
Alex



User avatar
XJSRider
Posts: 160
Joined: Fri Jul 24, 2020 2:45 pm
Location: New Britain, CT
Motorcycle: 1993 GL1500A

Re: Broken exhaust stud

Post by XJSRider »

I would spray that sucker with penetrating oil then lightly tap the stud with a hammer. Do this many times over the course of a couple days. At that point:

1. If no welder: Grab that sucker with a set of vice grips, say a little prayer to motorcycle gods and try your luck. Hopefully you don't shear the stud off. Make sure you did the penetrating oil and tappa tappa tap many times.

2. If you have a welder: Maybe try step 1 anyway, if no luck, slip washer over stud (should fit tight to stud), then a nut (doesn't need to thread on) and weld the nut to the stud. Use a wrench on the nut to remove the stud. Don't start wrenching immediately after welding, the stud will be hot and expand. Let it cool down and shrink a bit. The heat/cool cycle will help break it loose. Washer is there to keep you from welding to the case.

Good luck.

PS I reused those seals didn't have any problems.

PPS I DID replace the copper crush washers where header meets exhaust port as mine were absolutely smashed. This was the best price I could find and they fit fine:

https://www.ebay.com/itm/6-Pack-Exhaust ... 2749.l2649

User avatar
Rednaxs60
Posts: 2393
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD
1995 GL1500 SE CDN Edition
2012 Suzuki DL1000 VStrom
2008 GL1800 (sold)
Ontario 1985 GL1200 LTD (sold)

Re: Broken exhaust stud

Post by Rednaxs60 »

I would use a propane torch and do a heat/cool procedure combined with a good penetrating oil. The stud and head will expand at different rates, hopefully freeing up the stud enough to get it out - after each heat/cool take a vice grip and give it a twist. Should use a new exhaust gasket at the collector if you remove the pipes. Worse case is head will have to come off.
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

User avatar
agedbikeman
Posts: 138
Joined: Tue Jun 18, 2019 3:41 pm
Location: Bruay la Buissiere, France
Motorcycle: 1995 GL1500 Aspencade with Insta trike
2014 Can-Am Spyder RT(sold, glad to see the back of it)

Re: Broken exhaust stud

Post by agedbikeman »

Thanks guys, I'll try the heat cool procedure over the weekend, there's a broken stud on the left aswell but that downpipe is not coming off so I'm going to leave that one alone. it wasn't leaking to start with so I don't see it leaking now.

I've got an arc welder but I'm not confident with it so near alloy.

I've also got a mini chef's blowlamp with a pencil size flame, I'm going to give that a go.


Cheers guys, have a good weekend

User avatar
MikeB
Posts: 3091
Joined: Fri Dec 04, 2009 12:54 pm
Location: Tacoma, WA
Motorcycle: 1998 - GL1500 Aspencade
184K Miles
2017 - GL1800 Audio Comfort
14K Miles
Contact:

Re: Broken exhaust stud

Post by MikeB »

Check this You Tube video:


   Never miss a video: Subscribe to the GoldwingDocs YouTube channel today!


This guy is using a MIG welder but the same results can be achieved with a stick welder or a TIG welder.
MikeB
1998 - GL1500 w/184,500 miles ~ 2017 - GL1800 w/13000 miles
USAF Avionics Communications Tech - 1968 - 1986 / Flight Engineer C-130E - C-141B - 1986 - 1992. Retired
Industrial Maintenance Tech - 1992 - 2014
Retired in Tacoma, WA

User avatar
MikeB
Posts: 3091
Joined: Fri Dec 04, 2009 12:54 pm
Location: Tacoma, WA
Motorcycle: 1998 - GL1500 Aspencade
184K Miles
2017 - GL1800 Audio Comfort
14K Miles
Contact:

Re: Broken exhaust stud

Post by MikeB »

Here is another You Tube video where the guy is using a Stick Welder.



   Never miss a video: Subscribe to the GoldwingDocs YouTube channel today!
MikeB
1998 - GL1500 w/184,500 miles ~ 2017 - GL1800 w/13000 miles
USAF Avionics Communications Tech - 1968 - 1986 / Flight Engineer C-130E - C-141B - 1986 - 1992. Retired
Industrial Maintenance Tech - 1992 - 2014
Retired in Tacoma, WA

User avatar
XJSRider
Posts: 160
Joined: Fri Jul 24, 2020 2:45 pm
Location: New Britain, CT
Motorcycle: 1993 GL1500A

Re: Broken exhaust stud

Post by XJSRider »

mig is nice choice for stuff like this. Looked like he was using flux core in the vid (no nozzle for shielding gas).

This has saved me before lol.

But torch and vice grips also works well if there is something to grab onto.

Good luck OP!

89 1500
Posts: 144
Joined: Sat Jul 19, 2014 2:29 pm
Location: Texas
Motorcycle: 89, 1500 candy wineberry gone to another owner
92 Aspencade Cambridge blue

Re: Broken exhaust stud

Post by 89 1500 »

I broke one off in my 92. The front inside one on the left side. There was enough exposed to clamp my small vice grips on. Came out easy enough though.

User avatar
agedbikeman
Posts: 138
Joined: Tue Jun 18, 2019 3:41 pm
Location: Bruay la Buissiere, France
Motorcycle: 1995 GL1500 Aspencade with Insta trike
2014 Can-Am Spyder RT(sold, glad to see the back of it)

Re: Broken exhaust stud

Post by agedbikeman »

Been heating, tapping and jiggling all day, maybe I need better vice grips, trouble is good tools are hard to find here, it just won't budge it only broke at the bottom of the thin thread, there's a good bit sticking out to grab hold of but it just won't move, the grips eventually slip off because it's tapered, filed 2 flats on it, no different.

I'm about to give up and go for the drilling and re tapping method, I've got some very effective cobalt drill bits. for drilling stainless steel, so the studs won't be a problem for it.

I've got a stick welder but don't like the idea of using it because of the flying slag, watched the youtube video using welder, but didn't burn a bit of the alloy away, I'd be too scared of that, don't want to start removing heads.

If it don't budge tomorrow, out comes the drill and center punch. I'll start with 3mm and go from there

User avatar
ct1500
Posts: 1427
Joined: Wed Nov 10, 2010 8:09 pm
Location: Glastonbury,CT
Motorcycle: 1988 GL1500
Contact:

Re: Broken exhaust stud

Post by ct1500 »

I know it is too late now but applying heat to the nuts prior to removal would prevent breakage of the studs.
Local and need repair help with your 1500, Valkyrie or ST please click contact
Nothing leaves my shop till its' perfect
This is what I do

User avatar
agedbikeman
Posts: 138
Joined: Tue Jun 18, 2019 3:41 pm
Location: Bruay la Buissiere, France
Motorcycle: 1995 GL1500 Aspencade with Insta trike
2014 Can-Am Spyder RT(sold, glad to see the back of it)

Re: Broken exhaust stud

Post by agedbikeman »

Not too late, I wanted to remove the left downpipes, there is also 1 broken stud and 1 stuck, I'm scared to undo it as it was tighter than the rest, I will heat it and take it gently.

Thank you CT1500

fnickel
Posts: 98
Joined: Mon Oct 29, 2012 7:59 pm
Location: Campbellville, ON, Canada
Motorcycle: 1992 GL1500SE

Re: Broken exhaust stud

Post by fnickel »

I had the same issue a couple of years ago. The heat/cool cycle and much tapa/tapa helped, and then when grabbing it with vice grips, do only very small movements in both directions, loosening only in ever increasing small increments. Don’t try to loose it completely in one fell swoop. Mine did start to move slightly, and did come out quite easily after getting some small movement initially.

User avatar
Rednaxs60
Posts: 2393
Joined: Wed Nov 18, 2015 12:44 pm
Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD
1995 GL1500 SE CDN Edition
2012 Suzuki DL1000 VStrom
2008 GL1800 (sold)
Ontario 1985 GL1200 LTD (sold)

Re: Broken exhaust stud

Post by Rednaxs60 »

Stud(s) have been in there for some 25 years, patience and as fnickel mentions, little at a time. Pen oil is good, but hard for a fluid to flow uphill. Good vice grips are a necessity.
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

User avatar
Swagonmaster
Posts: 106
Joined: Sun Apr 16, 2017 3:30 pm
Location: Stokesdale, NC
Motorcycle: 1990 gl1500 SE

Re: Broken exhaust stud

Post by Swagonmaster »

While you are trying the heat and tap thing, get it as hot as your torch allows and press a candle to the broken stud. Believe it or not it really works possibly because the candle wax doesn't flash off like penetrating oil does and allows the wax to get up in the threads.
Try to learn from the mistakes of others..... you won't live long enough to make them all yourself!

User avatar
agedbikeman
Posts: 138
Joined: Tue Jun 18, 2019 3:41 pm
Location: Bruay la Buissiere, France
Motorcycle: 1995 GL1500 Aspencade with Insta trike
2014 Can-Am Spyder RT(sold, glad to see the back of it)

Re: Broken exhaust stud

Post by agedbikeman »

Continuing story of broken exhaust stud 2, now hope I've not ruined the head beyond hope :o
having got the first one out I thought we have the technology, how stupid of me to think like that,
I heated, tapped, sprayed, did everything you guys told me to try, nope it wouldn't budge, so I finally got out the drill and cobalt bits, did a dummy drilling on stud 1 (removed) to see how hard the metal was, cobalt drills whizzed through it, so here we go on stuck stud 2. as usual no way you could get the center punch dead center, FYI, the stud hole is twice as deep as the stud thread, went slowly with a 3mm bit til it was through, then a 4mm, but wasn't so careful, drilled the hole on the head even deeper than it was, carried on with a pen mark on each drill, 5,then 6 then 7mm, finally not enough left of the stud to be stuck, and unscrewed it.
Pushed a rod into the hole and it still had a solid bottom, no liquids emitted from it, screwed in a bolt to test, thread ok.

This is the stud stud, the front most one, so you know where I'm coming from
This is the stud stud, the front most one, so you know where I'm coming from


This is just a photo of a head on Ebay, not my one, just to see where the drill might have gone if I'd not stopped when I did
This is just a photo of a head on Ebay, not my one, just to see where the drill might have gone if I'd not stopped when I did


This is what's left of the stud after drilling, I didn't use an 8mm drill I stopped at 7mm
This is what's left of the stud after drilling, I didn't use an 8mm drill I stopped at 7mm

Just hope I've not caused any problems by accidently deepening the stud hole.
If anyone has a head lying around maybe you could look to see what damage could be caused if I'd deepened the hole too much, where the hole would have ended up.

Thank guys for you help and putting up with my waffle.
Alex

User avatar
XJSRider
Posts: 160
Joined: Fri Jul 24, 2020 2:45 pm
Location: New Britain, CT
Motorcycle: 1993 GL1500A

Re: Broken exhaust stud

Post by XJSRider »

Man what a PITA!!!! Glad you got it out without trashing the threads. I think you'll be ok with the slight overdrill doesn't look like you would have hit anything.

User avatar
Swagonmaster
Posts: 106
Joined: Sun Apr 16, 2017 3:30 pm
Location: Stokesdale, NC
Motorcycle: 1990 gl1500 SE

Re: Broken exhaust stud

Post by Swagonmaster »

As long as you didn't drill into another passage then no harm has been done. If you really want to be paranoid then probe around at the bottom of the hole with an awl to see if the metal is so thin that you can poke a hole in it.
Try to learn from the mistakes of others..... you won't live long enough to make them all yourself!

User avatar
agedbikeman
Posts: 138
Joined: Tue Jun 18, 2019 3:41 pm
Location: Bruay la Buissiere, France
Motorcycle: 1995 GL1500 Aspencade with Insta trike
2014 Can-Am Spyder RT(sold, glad to see the back of it)

Re: Broken exhaust stud

Post by agedbikeman »

Did that, only found solid bottom of hole, If I had drilled into another passage, I suppose I could have put a short grub screw in with loctite. I think the only passages would be oil or water and there was no sign of any liquid in the hole.

If they'd have used stainless nuts and 8mm paralell studs we wouldn't have this problem, but that would've added 50 cents to a 20,000 dollar bike

Alex

User avatar
Swagonmaster
Posts: 106
Joined: Sun Apr 16, 2017 3:30 pm
Location: Stokesdale, NC
Motorcycle: 1990 gl1500 SE

Re: Broken exhaust stud

Post by Swagonmaster »

Now your next big issue, do you use antisieze or locktite to put the studs in with?
Try to learn from the mistakes of others..... you won't live long enough to make them all yourself!

User avatar
XJSRider
Posts: 160
Joined: Fri Jul 24, 2020 2:45 pm
Location: New Britain, CT
Motorcycle: 1993 GL1500A

Re: Broken exhaust stud

Post by XJSRider »

Swagonmaster wrote:
Tue Sep 15, 2020 5:57 pm
Now your next big issue, do you use antisieze or locktite to put the studs in with?
This made me laugh.

User avatar
agedbikeman
Posts: 138
Joined: Tue Jun 18, 2019 3:41 pm
Location: Bruay la Buissiere, France
Motorcycle: 1995 GL1500 Aspencade with Insta trike
2014 Can-Am Spyder RT(sold, glad to see the back of it)

Re: Broken exhaust stud

Post by agedbikeman »

LOCKTITE!!!!!!! :o :o :o :o :o :o heaven forbid, I always thought it was the tread that held a nut and bolt together, if it's that critical use a spring washer, what did us bikers do before Locktite, our bikes didn't fall to bits en route, anti sieze of course, exhaust can't fall off even if you lost every nut, talking of nuts, I'd like to meet the nut that designed this exhaust, what's all this copper woven sealing collar rubbish, pipe slips into pipe do up the clamp, never seen anything like it before, easy on, easy off, and paint it to stop rust.
Now you're getting me started on a different rant (as us old gits are inclined to).
the answer is I have ceramic high temperature anti sieze paste.

User avatar
Swagonmaster
Posts: 106
Joined: Sun Apr 16, 2017 3:30 pm
Location: Stokesdale, NC
Motorcycle: 1990 gl1500 SE

Re: Broken exhaust stud

Post by Swagonmaster »

I thought I would get a reaction from that. :lol:
Try to learn from the mistakes of others..... you won't live long enough to make them all yourself!

Old Fogey
Posts: 835
Joined: Fri Oct 30, 2009 2:09 am
Location: Glasgow Scotland
Motorcycle: 1976 GL1000
1979 GL1000
Contact:

Re: Broken exhaust stud

Post by Old Fogey »

Loctite is not as stupid as you might think. Not for holding the stud in but for forming a barrier between the steel stud and the alloy head. It works as an anti seize if you don't have anything else to hand.
'Impossible' is just a level of difficulty! The only stupid question is the one you didn't ask first!

( Seriously, you haven't read all 115 pages of my http://www.wingovations.com website ?? :shock: )

User avatar
agedbikeman
Posts: 138
Joined: Tue Jun 18, 2019 3:41 pm
Location: Bruay la Buissiere, France
Motorcycle: 1995 GL1500 Aspencade with Insta trike
2014 Can-Am Spyder RT(sold, glad to see the back of it)

Re: Broken exhaust stud

Post by agedbikeman »

I have a pot of ceramic grease, anti sieze assembly paste, works up to 1500 degrees centigrade, also good for the rubber grommets on the side panels so you don't break the pins getting them off.

I had enough of loctite when I had a Can Am Spyder, every bolt was coated to excess as if Can Am had shares in Loctite, we didn't need it in the old days and a GL1500 is now the old days.

User avatar
Swagonmaster
Posts: 106
Joined: Sun Apr 16, 2017 3:30 pm
Location: Stokesdale, NC
Motorcycle: 1990 gl1500 SE

Re: Broken exhaust stud

Post by Swagonmaster »

There is a time and place for both products but I was joking, unless you were trying to stop a leak past the threads Loctite wouldn't be what I would use either.


Try to learn from the mistakes of others..... you won't live long enough to make them all yourself!

Post Reply