what is it people say..."if it aint broke dont fix it"....there was no good reason for me to remove the exhaust system other than me being curious. Now here i find myself with a broken exhaust stud! Thats where you guys come into the picture. Any1 sufferd the same thing and if so how do i go about getting the rest of the stud out? there is enough of the stud proud of the exhaust port to be able to be gripped with say a pair of plires. Guys any thoughts or answers will be greatly received.
Can you spot weld a nut on the left over thread? In the past I have put say three nuts on a bit of thread and then crack them up tight together then undo the bolt using the 3rd one in this has some times worked on stuff
Best bet tho would be a nut welded on as that won't slip, we try plenty of wd40 or equivalent as well over night
Lots and lots of WD40 will help, spray it on a daily basis and let it work it's way in. Before removing anything like this I spray loads in everyday for about a week while still using the bike as my transport. I find this helps greatly before even starting the job. Consider it prep work
Depending on how much thread you have left to play with, give it a good soak as above and then clamp some mole grips on and you may get lucky. Otherwise it's weld a nut on as suggested or drill the old bolt out being careful not to damage the thread on the head. It may need re tapping or you may have got enough of the old bolt out that a new one will re thread itself.
Thats a Bugger!
The hindsight answer is to use a nut splitter, but its too late for that now
as for removal, someone on here also worked out that if you use a dremmel cutting disc to slice off the first 1mm or aluminium from the cylinder block, without cutting through the stud, it will then unscrew by hand. the corrosion is at the outer surface and with that removed it is easy to remove. As the exhaust is not bolted to that cast face, there is no problem with removing any metal, so it is a good option.
Tnx for all the reply's guys, its a bit of a head scracher at the mo. But at least iv got some ideas to play with. Ill keep ya posted
Im gunna order a can of that gear Seb so tnx m8
what is it people say..."if it aint broke dont fix it"....there was no good reason for me to remove the exhaust system other than me being curious. Now here i find myself with a broken exhaust stud! Thats where you guys come into the picture. Any1 sufferd the same thing and if so how do i go about getting the rest of the stud out? there is enough of the stud proud of the exhaust port to be able to be gripped with say a pair of plires. Guys any thoughts or answers will be greatly received. 
cheers Seb 
It would be a good one to have on the shelf.