Broken cylinder head studs on an 85 Honda 250 SX Three Wheeler?

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ScottR

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It is just a steel stud screwed into an aluminum head?

Go to a hardware store that sells heli-coil or other similar repairs, get a drill and a tap the next size larger than the stud, drill it and tap for a or 2 mm larger stud.

You might have to make the hole in your exhaust manifold bracket a little bigger, but this is the easy and quick fix.
 
A few months ago, my uncle gave a an old three wheeler that had been sitting in the back of the barn and had not ran in a few years. He also gave us an identical bike that he was using for parts, since it had only one tire, the back end was completely destroyed, and was only kept for parts. The engine is still good on the old one. My uncle said if we could get the good bike running, we could keep it.

Me and my brother got it running after robbing a carburetor, a spark plug, a gas tank (the old one was rusted and dented) and the awesome but expensive rack off the parts bike. She runs (but since the battery's no good, we jump it off my truck battery), and all she needed was a battery and a new muffler (it didn't have one when we got it.)

My brother was taking off the old muffler's header pipe (it was still on there), and the nut was twisting, but the stud twisted off. On the other side, I hosed the nut with WD40 and scrubbed it down with a wire brush. Bad news: I accidentally rounded the bolt. So my uncle cut it off with a Saw All.

So we got the new muffler but we can't put it on, because one stud was broke in half and my uncle sawed off the other one. Him and another uncle tried to heat the studs and get it out with an Easy Out, but it didn't work. They were just melting the head. So we took it to a nearby machinist, and he said he couldn't get it out. (He had better equipment, but tried the same method) At that point my first Uncle (Uncle Mike) and my other uncle (Jeff) decided we should just take off the old cylinder head and rob the other one off the parts bike.

Mike called yet another uncle (William, he used to work at a Honda Motorcycle shop) for advice, and he said it's be more trouble than it's worth. Instead, William referred us on one of our cousins a few towns over who owns a motorcycle and auto repair shop. he said, "If anyone can get it out, it's him."

I called him and he said he'd look at it Sunday. But what if he can't? Is there any other way to get them out?
 
It is just a steel stud screwed into an aluminum head?

Go to a hardware store that sells heli-coil or other similar repairs, get a drill and a tap the next size larger than the stud, drill it and tap for a or 2 mm larger stud.

You might have to make the hole in your exhaust manifold bracket a little bigger, but this is the easy and quick fix.
 
It is just a steel stud screwed into an aluminum head?

Go to a hardware store that sells heli-coil or other similar repairs, get a drill and a tap the next size larger than the stud, drill it and tap for a or 2 mm larger stud.

You might have to make the hole in your exhaust manifold bracket a little bigger, but this is the easy and quick fix.
 
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