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#1 |
Join Date: Mar 2018
Location: Texas
Posts: 29
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Magician exhaust plate stud broke off and pipe broken from frame
Hello all!
I have been having a blast riding my Magician out and about but I have an issue now and am trying to fix it. https://photos.app.goo.gl/LYAor5w0cS78MTg22 https://photos.app.goo.gl/ggUb9jSddkfCpus96 So I am thinking of drilling and then what would I used to extract it, a screw or something like that. I noticed the thread http://chinariders.net/showthread.ph...ust+bolt+broke about it but am not sure exactly what will work. My other problem is the exhaust pipe broke off the frame, is this safe to leave or should I get it welded back on? Or maybe any other suggestions? |
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#2 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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Since you said "get it welded back on", I presume you don't have a welder; that precludes the method of welding a nut onto the broken stud.
If you decide to drill the broken stud out, find a quality industrial tool shop that sells good quality drill bits (like cobalt) as well as left hand drill bits (not joking). Select a size that is roughly half the diameter of the stud. The idea is to use a center punch to locate the middle of the stud, drill into the stud (slowly) and then drill into it again (even more slowly) with a slightly larger left hand drill bit (this time with the drill in reverse). If everything goes your way, the left hand drill bit will catch on the stud as it removes material, causing the broken stud to spin right out. It's magic when it works properly. I stay away from extractors and easy-outs, because I've broken more than I've been successful with. Left hand drill bits have been very successful for me. It's a good idea to extract the other stud and measure the hole depth, so you don't drill too deeply. Rather than welding the tab back onto the stock exhaust, perhaps the eBay exhaust that several members have installed on Hawks would work on your bike. Somebody smarter than me needs to chime in there.
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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#3 | |
Join Date: Mar 2018
Location: Texas
Posts: 29
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Quote:
I will have to research that exhaust for the Magician unless like you said someone might know. |
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#4 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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You have the process exactly right. Ask for the best quality bit for drilling steel; I suspect they'll offer a cobalt bit.
I think this is the exhaust that Hawk owners are using, but I'm not sure: https://www.ebay.com/itm/Aluminum-Ex...Na4sl1&vxp=mtr
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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#6 |
Join Date: Apr 2017
Location: Omaha, NE
Posts: 8,100
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I have seen one Magician using the same eBay CRF230 exhaust that us Hawk owners use. While it does fit, I do believe it has to be modified a bit for the muffler to work, and you can tell by looking that it isn't really meant for the bike. It's a little on the long side.
There are a couple of exhausts made for the Magician style bikes that can be found on TaoBao. This OTOM exhaust is one, and comes with a removable silencer. http://www.engtaobao.com/item/taobao/547695211685.html
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Hawk Information and Resource guide: http://www.chinariders.net/showthread.php?t=20331 2018 Hawk 250 - Full Mod list here. http://www.chinariders.net/showpost....62&postcount=1 2024 Royal Enfield Shotgun 650 https://chinariders.net/showthread.php?t=34124 |
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#7 |
Join Date: Mar 2018
Location: Texas
Posts: 29
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It's looks like I won't be getting the stud out after all... Where can I get a new Cylinder Head for my magician 250?
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#8 |
Join Date: Jun 2016
Posts: 11
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Use The Head You've Got
I have a Hawk and also faced the problem of a broken off exhaust stud. I took the engine out of the frame and tried to remove the remaining stud and that one also wrung off. Rather than extract the broken pieces still in the cylinder head I drilled and tapped new holes beside the old stud locations. There is enough room for them. A machine shop I consulted recommended I drill the new holes to a depth 1.5 times the diameter of the replacement studs. I did and the new studs are still holding fine after several months. So, you may be able to use your head (the one you've already got) to hold your Magician together.
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#9 | |
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Join Date: Oct 2016
Location: Houma, La.
Posts: 11,655
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2024 Linhai 300 ATV 4x4 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S (Sold) 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel |
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#11 | |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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Quote:
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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#12 | |
Moderator
Join Date: Oct 2016
Location: Houma, La.
Posts: 11,655
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2024 Linhai 300 ATV 4x4 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S (Sold) 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel |
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#13 |
Join Date: Mar 2018
Location: Texas
Posts: 29
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Thanks JerryHawk for the idea! I will try to get the other stud out with some vice grips and take that to Autozone to get another one with the larger base stud for the other one. What size stud should I be looking to get?
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#14 | |
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Join Date: Oct 2016
Location: Houma, La.
Posts: 11,655
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2024 Linhai 300 ATV 4x4 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S (Sold) 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel |
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#15 |
Join Date: Apr 2017
Location: Omaha, NE
Posts: 8,100
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Just going to make this suggestion, but if you take the head in to a local machine shop, they can probably extract that stud without damaging the threads for a relatively small fee.
Worst case scenario, order a replacement head through CSC for the TT250. The only real difference will be that you need to make a block off plate for the air injection port on the exhaust side. $85 for a complete head already painted black and ready to go.
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Hawk Information and Resource guide: http://www.chinariders.net/showthread.php?t=20331 2018 Hawk 250 - Full Mod list here. http://www.chinariders.net/showpost....62&postcount=1 2024 Royal Enfield Shotgun 650 https://chinariders.net/showthread.php?t=34124 |
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Tags |
magician, magician 250cc |
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