March 17th, 2014, 09:10 AM | #1 |
Its not a 250,its a Ninja
Name: Shaun
Location: Little Rock, AR
Join Date: Jun 2012 Motorcycle(s): '11 CBR250R, '22 CFMOTO 300NK Posts: 278
|
Exhaust header stud broke
Ok, so you may have seen my post in the for sale section regarding my exhaust. I was removing it a couple weeks ago, and then my wife and kids and I all got sick (yuk) and now I am back into repair mode.
Anyways, as I was taking off the nuts on the header, both of the inner studs broke off. I am freaking out pretty bad, and I am hoping that someone can help me out with a fix to this. The rust is major on the bolt stud and nut, but the header is only slightly rusted. This seems to me to be an issue the previous owner did not address when they changed the exhaust. All help is appreciated. |
|
March 17th, 2014, 09:32 AM | #2 |
Daily Ninjette rider
Name: Hernan
Location: Florida
Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot.
MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16
|
Steel that bolts into aluminum always cause a corrosion that tends to weld both metals.
The above could be the reason for the need to apply extra torque on those nuts that sheared the bolts. The studs need to be removed from the cylinder, but first, you need to soak those for some good time with some penetrating oil; my favorite is a mix of acetone and marvel oil. Finally, if you have nothing to grab them with, you will need a stud's extractor or taking the bike to a machine shop for them to use theirs.
__________________________________________________
Motofool .................................Never ride faster than your guardian angel can fly "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí |
|
March 17th, 2014, 12:34 PM | #3 | |
Its not a 250,its a Ninja
Name: Shaun
Location: Little Rock, AR
Join Date: Jun 2012 Motorcycle(s): '11 CBR250R, '22 CFMOTO 300NK Posts: 278
|
Quote:
Do you have a preferred mix of the acetone/marvel oil, 50/50? And will vicegrips work to take those out, after a good soak? Last futzed with by jcgss77; March 17th, 2014 at 12:36 PM. Reason: lmgtfy |
|
|
March 17th, 2014, 12:47 PM | #4 | |
Daily Ninjette rider
Name: Hernan
Location: Florida
Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot.
MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16
|
Quote:
You can replace the Marvel Oil with ATF or Air Tool Oil. http://www.marvelmysteryoil.com/ If it is really bad, vice-grips may not be able to hold the stud strongly enough, but I would try that first. Avoid drilling the things out, as precise centering is difficult and it is easy to destroy the aluminum threads. http://advrider.com/forums/showthrea...ighlight=studs
__________________________________________________
Motofool .................................Never ride faster than your guardian angel can fly "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí |
|
|
March 23rd, 2014, 11:15 AM | #5 |
ninjette.org member
Name: Baz
Location: Takoma Park, MD
Join Date: Jan 2014 Motorcycle(s): 2000 EX250 Ninja Posts: 59
|
I've been there and I sympathize. It's true, drilling can make things even worse. Hopefully soaking and vice grip method will work.
If not, there's Spark Erosion. An electrical current is attached to the offending stud and the metal is eroded and broken up. A high school shop teacher did it for me on my old Suzuki and it worked great. If all else fails, call around to some electrical shops or machine shops and ask if they do it. It's not a difficult process and they shouldn't charge much. Good luck. |
1 out of 1 members found this post helpful. |
March 23rd, 2014, 11:49 AM | #6 | |
Participant
Name: Dave
Location: South of Seattle
Join Date: Oct 2012 Motorcycle(s): '94 K75 std Posts: Too much.
MOTM - Aug '15
|
Quote:
Automatic transmission fluid and acetone (50/50 mix) is my favorite. |
|
1 out of 1 members found this post helpful. |
March 23rd, 2014, 01:02 PM | #7 |
ninjette.org member
Name: jim
Location: texas currently in Temecula Valley CA
Join Date: May 2013 Motorcycle(s): honda crf230l & 2013 ninja 300se wife has Honda crf230l & honda cbr250r repsol Posts: 222
|
i've removed them by welding a nut to the broken stud. The heat from welding seems to break them loose.
|
1 out of 1 members found this post helpful. |
March 25th, 2014, 05:12 AM | #8 |
pregens for the win!
Name: Andrew
Location: Los Angeles
Join Date: Mar 2014 Motorcycle(s): 07 ninja 250, 07 yamaha r6 Posts: 77
|
^^^this. if you have a butane torch try heating up the stud for a couple minutes. It's the preferred solution for removing o2 sensors that are stuck without damaging them. I don't see why it wouldn't work here as well.
"liquid wrench" is another good penatrating oil, always worked for me. |
|
March 25th, 2014, 08:49 AM | #9 |
ninjette.org guru
Name: harry
Location: Central Florida
Join Date: Sep 2013 Motorcycle(s): 2006 Ninja 250, 2004 Buell XB12s, Honda 110 Elite Posts: 332
|
If it breaks flush, pull the head and take it to a machine shop. (Call around to find one that does this) It is correctly called E.D.M. (Electrical Discharge Machining). Correctly done, they can remove the broken stud completely without damaging the threaded hole.
I said pull the head because most shops will not attempt it with the head in place due to access difficulty. Hopefully you can get it out. The welded nut/solvent soak is a very good and usually productive idea.
__________________________________________________
"They don't pay me enough to ride this thing!" Kenny Roberts after winning the Indy Mile on the TZ750 powered Grand National bike. |
1 out of 1 members found this post helpful. |
March 27th, 2014, 05:17 PM | #10 |
ninjette.org guru
Name: Lee
Location: Monroe, LA
Join Date: Feb 2014 Motorcycle(s): Rebel 250s, Ninja 250s VN750s (currently nine total) Posts: 465
|
|
1 out of 1 members found this post helpful. |
March 27th, 2014, 05:32 PM | #11 |
ninjette.org certified postwhore
Name: Eric
Location: Iowa City
Join Date: May 2009 Motorcycle(s): 2008 Kawmeracchi 350 2010 Project X Posts: A lot.
Blog Entries: 54
MOTM - Sep '18, Feb '16
|
To fix this really takes skill time and a little luck.
PB blaster is extremely effective. Heating the broken stump just a little with a propain torch then spray PB Blaster on it. Let it sit for a couple days or over night. Then go after it with a very small drill. Drill a tiny little hole straight through the broken stud. Then heat it up just a little and soak it with PB Blaster again let it soak over night. Next step is a reverse drill. This will follow the little hole and if you are lucky it will pull the broken stud. This all seems like a boat load of trouble. But that is what it takes. If you drill through the stud with a backward drillbit then it can be completed with my favorite thread repair kit. WWW.Timesert.com Or pull the head and give it to a machine shop. Like I said this is either a skill fix or luck fix. But it can all go wrong instantly. Like if the drill brakes off in the stud. Remember the stud is harder on the outside. So if you drill crooked you are headed for disaster.
__________________________________________________
Top speed 123.369mph. Ohio mile Worlds fastest 250 ninja |
1 out of 1 members found this post helpful. |
March 30th, 2014, 07:30 AM | #12 |
ninjette.org member
Name: Tim
Location: Quad Cities
Join Date: Sep 2012 Motorcycle(s): Ninja 250 Posts: 102
|
I had one break and I put two nuts on the stud so i could use a wrench. I heated the aluminum with a torch a little bit. Not enough to get it too hot, but I let it heat for a minute or two to expand it.
__________________________________________________
Motorcycle noob, feel free to ignore me. |
|
March 31st, 2014, 04:09 AM | #13 |
pregens for the win!
Name: Andrew
Location: Los Angeles
Join Date: Mar 2014 Motorcycle(s): 07 ninja 250, 07 yamaha r6 Posts: 77
|
Any updates? Did you get the stud out of the head?
|
|
March 31st, 2014, 07:11 PM | #14 |
Its not a 250,its a Ninja
Name: Shaun
Location: Little Rock, AR
Join Date: Jun 2012 Motorcycle(s): '11 CBR250R, '22 CFMOTO 300NK Posts: 278
|
Still soaking it. I am ordering a stud extractor, so it will give it a good amount of time to break loose so I can hit it with that.
So, thinking forward, I really don't think I will be installing new studs there, is there any problem with using just bolts to mount the exhaust headers? I will be going to stock headers, and was considering using stainless steel bolts. Anyone else replace the studs with bolts? |
|
March 31st, 2014, 07:29 PM | #15 |
Daily Ninjette rider
Name: Hernan
Location: Florida
Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot.
MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16
|
Wear of the aluminum threads and length of bolt needing to be less than the threaded depths (but no much shorter or aluminum threads will be overloaded).
__________________________________________________
Motofool .................................Never ride faster than your guardian angel can fly "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí |
|
February 3rd, 2020, 08:03 AM | #16 |
ninjette.org member
Name: Cyril
Location: no-town
Join Date: Aug 2019 Motorcycle(s): Ninja 250 EX x2, 07" CBR600RR, 09"SFV 650 Gladius Posts: 29
|
Sorry for revving thread, but does anyone know the size and diameter for replacement Exhaust Studs? I can't seem to find them at all...
|
|
February 3rd, 2020, 08:55 AM | #17 |
ninjette.org certified postwhore
Name: Gordon
Location: new york
Join Date: Sep 2009 Motorcycle(s): '95 DUCATI 900SS/SP '07 DUCATI SS800 '19 HONDA CBR650R Posts: A lot.
MOTM - Nov '18, Mar '17
|
6mm x 27mm kaw part# 92004-066
__________________________________________________
Custom Carb Service |
|
February 3rd, 2020, 08:58 AM | #18 |
ninjette.org member
Name: Cyril
Location: no-town
Join Date: Aug 2019 Motorcycle(s): Ninja 250 EX x2, 07" CBR600RR, 09"SFV 650 Gladius Posts: 29
|
|
|
Similar Threads | ||||
Thread | Thread Starter | Forum | Replies | Last Post |
Header Stud Came Out of the Block?? | Dsheumaker | 2008 - 2012 Ninja 250R Tech Talk | 4 | March 30th, 2015 08:58 PM |
Single Exhaust Header | Shintoxica | 1986 - 2007 Ninja 250R Farkles | 5 | September 12th, 2013 05:56 AM |
Area P Exhaust Broke, Bummer!!! | Manimal | 2008 - 2012 Ninja 250R Tech Talk | 11 | July 16th, 2011 07:16 PM |
FS: NEW Area-P exhaust header | Momaru | Motorcycle-related | 6 | June 8th, 2011 03:02 PM |
Header exhaust gasket | B2FiNiTY | 2008 - 2012 Ninja 250R Tech Talk | 5 | May 8th, 2009 08:03 PM |
|
|