Advice needed

[darkember]

Give it more heat !
Did you remove 3 mm from the engine ?

Not as yet as I have a decent flats on what was left of the stud. Wont removing 3 mm cause the manifold not to sit straight on re-assembly??

[lloydie]

It will fit fine as it sits away from it anyway .
Before removal of 3mm


After 3mm has been removed


As you can see in the pics removing 3mm from the area around the studs won't effect the fitment of the headers .
What removing 3mm will do is remove the corrosion area and will aid removal of the stud

[darkember]

How does this look or should I take more off?

[lloydie]

now get some heat on it and tap the stud with a hammer and unwind it at the same time

[darkember]

now get some heat on it and tap the stud with a hammer and unwind it at the same time

I assume you have reached the stud when the sparks start to fly instead of the allu dust:)

[lloydie]

now get some heat on it and tap the stud with a hammer and unwind it at the same time

I assume you have reached the stud when the sparks start to fly instead of the allu dust:)

oh yes so dont cut into the stud

[macdee]

now get some heat on it and tap the stud with a hammer and unwind it at the same time

hurry up darkember i cant leave to go work outside until you get this sorted

[darkember]

Still not budging as yet but going in the right direction. Ordered some more cutting disks as I only removed 1.5 mm & ran out of disks. Will have another bash at it next week after removing another slice of allu and creating & new set of flats for the spanner.

[Jamoi]

Do you have a file? I just used a file to create flats on the thread, heated it up, got a spanner on it and tapped the end of the thread with a hammer while giving the spanner some welly

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[darkember]

Do you have a file? I just used a file to create flats on the thread, heated it up, got a spanner on it and tapped the end of the thread with a hammer while giving the spanner some welly

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What size spanner did you use my stud will only fit a 6mm once the flats are done. I have checked my new replacement studs & an 8mm is far to big as is the 7mm

[Jamoi]

I used a big Bacho adjustable spanner, I didn't keep the nut on the end of the stud like you have though. I know adjustables are a bit of a swear word to the pro, but a quality one like Bacho worked fine. Give it a good thump with that hammer too ;) I.e not a Virt thump!

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[Jamoi]

P.s did you get your replacement studs from eBay? I did and the thread is much thinner on the nut end and the nut is a bit mickey mouse

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[darkember]

These are the ones I got but they were only £6 for a set of 4

http://www.ebay.co.uk/itm/261240553142

[Jamoi]

They do look to be of a better quality than mine

What sort of stage are you at now with the stud? Maybe stop for a bacon sarnie and come back to it!

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[Bleh]

One thing many many MANY experienced people have told me in the past and something I have become to truly believe is that the japs are fantastic are building bikes (and cars for that matter) and anything they put on a bike, they do so for a reason. Putting on more than necessary costs more and therefore reduces profit margins.

Another thing I am learning (doing a BEng at the moment) is that things aren't randomly chosen when being included in the design of a machine.

Obviously, other people have cut away (what appears to be 3mm) from the engine and haven't seen a problem but this genuinely concerns me. Surely, cutting away 3mm from where the stud is placed means you have 3mm less of thread acting on the manifold and against the forces subjected to that (not just gases traveling at just shy the speed of sound but also every time you hit a bump, gear changes, braking etc all act on all parts of the bike, gravity ensures it!). So if you only have 10mm thread on the stud and remove 3mm from its housing, you only have 7mm doing the same job 10mm is expected too. I'm not suggesting your going to run into problems as it's you likely wont, but I am suggesting that cutting bits of engine away from the bike should be last resort business.

There are several other methods you could attempt before resorting to this like someone has said already, the shocking method (almost the same effect as lubing and tapping with a hammer a few times a day, the principle of breaking the seal/ seizure remains the same).

Whatever you decide to do, I hope you get success from it without causing any excessive (and expensive) damage.

Again, good luck.