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So I had some luck, kinda.. I bought left handed bits and drilled slowly, stepping the size as I went. Never got the stud to back out, but I did remove material down so far as to start exposing the top of the threads. So I took a metric tap and ran it into the hole, sort of cutting out what was left of the screw.
So I bought new studs at NAPA, added some blue loctite, and installed. I’d say there is a thread engagement of about 60%, hopefully enough to get me another 1000 Miles if I’m careful. No 65mph 100 mile trips anymore... I’m sad about that. But I did take the double nut method which I would recommend doing to the stock machines as part of the setup procedure of these bikes.
I had NOT thought about the exhaust split point putting added stress on the studs, but that makes sense. I’m not sure what rubber part is being referred to but I just tighten the heck out of the metal connector and check it once in a while, is there a better way to provide support there?
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