Exhaust Stud Replacement?

davisbm2 · 11-13-2018, 09:14 AM

So TXpowersports will NOT warranty this part, even though the bike is 6 months old..

Hopefully I can extract my broken exhaust stud, but I really don't want this happen again.

Can anyone recommend a replacement? I'm not sure where to start. I keep thinking about going to the hardware store, buying a steel threaded rod, and cutting it to length (and I'm sure the threads are metric).

Should I order a new exhaust stud online? If so what is the best option?

ChrisWNY · 11-13-2018, 10:24 AM

Are you referring to the exhaust mount that is in the lower-middle part of the frame or the the one that holds the muffler in place? Unfortunately TX power sports won't take any responsibility for anything beyond shipping...once you receive your Hawk, you're more or less on your own. That's the one downside of owning a China bike...warranty's are nonexistent. If it's just an exhaust mount, it should be fairly inexpensive to have a new one welded on or use a clamp instead (depending on where it is).

**JerryHawk250** · 11-13-2018, 10:31 AM

You can pick up a new stud from your local auto parts. You can remove the broken stud by drilling it and use an easy out. This is what I use to remove broken studs on my truck. works great. https://www.lowes.com/pd/SpeedOut-8-...tor/1000170531

davisbm2 · 11-13-2018, 10:47 AM

Yep, I'm starting to see that with TX Powersports.

Would you guys consider an exhaust stud as an engine component? I argue yes because it literally comes from within the head and without it the engine will not operate correctly... But I suppose I could see as a non-engine part like a turn signal but that seems doubtful.

So just bring my good stud to Autozone and have them get a direct replacement?

I bought some stepped left hand drill bits, hopefully if I work slowly and carefully they should work.

Red Hawk · 11-13-2018, 12:22 PM

I would strongly caution you to use a milling machine to remove the stud. It would be a 4-5 minute job tops VS a trashed head. You must pull the head to do this.

I just pulled 8 studs on my 53 year old tractor head. They were all to hard to drill on an uneven broken stud. After the 2nd stud let go at 12Ft Lbs on the torque wrench I'd made up my mind.

Replace the stud with a good quality part, not an Ebay Far East one.

If this job goes sideways a time cert sleeve can still save it if the drill walks off.

Pm me if you want to use my mill.

**JerryHawk250** · 11-13-2018, 12:33 PM

If all else fails you can do what zippy did. http://chinariders.net/showpost.php?...&postcount=144

davisbm2 · 11-13-2018, 02:21 PM

Thanks for the advice here is my game plan:

1. Drill out the stud using left handed bits

2. If that fails, try to retap the hole to a bigger size using a mill/ press

3. If that fails, drill new holes like zippy using a mill/ press

4. If that fails, sell the bike for like $600 and save up for a 10 year old Japanese Dual Sport

5. If that fails, give up on motorcycles and find a new hobby. Maybe whittling.

**JerryHawk250** · 11-13-2018, 02:23 PM

Quote:

Originally Posted by davisbm2

Thanks for the advice here is my game plan:

1. Drill out the stud using left handed bits

2. If that fails, try to retap the hole to a bigger size using a mill/ press

3. If that fails, drill new holes like zippy using a mill/ press

4. If that fails, sell the bike for like $600 and save up for a 10 year old Japanese Dual Sport

5. If that fails, give up on motorcycles and find a new hobby. Maybe whittling.

Well lets hope 1,2, or 3 works. lol

llr · 11-13-2018, 05:28 PM

Left handed bits are a start but you will probably need an easy out too.

Weldangrind · 11-14-2018, 12:32 PM

I've had the best success with left handed bits by first drilling a small pilot hole using a conventional bit. The left hand bit then just follows the pilot, hogs out a bit of material and hopefully backs the stud right out.

Cravin01 · 11-14-2018, 06:02 PM

Sounds like a good game plan, Also.. Tell yourself you gotta go slow, it could take a long time, and my not work out all that well. That keeps my temperature down when it goes slow, takes a long time and doesn't work out that well. anything other than that is a win.

when you manage to get it fixed you can still whittle on your free time.

Good luck brother!

Ariel Red Hunter · 11-14-2018, 10:08 PM

Quote:

Originally Posted by davisbm2

So TXpowersports will NOT warranty this part, even though the bike is 6 months old..

Hopefully I can extract my broken exhaust stud, but I really don't want this happen again.

Can anyone recommend a replacement? I'm not sure where to start. I keep thinking about going to the hardware store, buying a steel threaded rod, and cutting it to length (and I'm sure the threads are metric).

Should I order a new exhaust stud online? If so what is the best option?

I would forget going the threaded rod route. Made from low quality steel...ARH

Chinabike · 11-16-2018, 01:19 AM

found it better just buying a new head

pete · 11-16-2018, 03:01 AM

Quote:

Originally Posted by Ariel Red Hunter

I would forget going the threaded rod route. Made from low quality steel...ARH

ARH..you can buy it in just about every grade known to man kind..
any thing other than mild steel / 250mpa is usaly not a stocked item
in most places..

.

Ariel Red Hunter · 11-16-2018, 03:47 PM

Quote:

Originally Posted by pete

ARH..you can buy it in just about every grade known to man kind..
any thing other than mild steel / 250mpa is usaly not a stocked item
in most places..

.

True. His problem is that the big box stores carry the absolute cheapest quality imaginable. And that is where most people in the States go to look...ARH

11-13-2018, 09:14 AM	#1
davisbm2 Join Date: Apr 2018 Posts: 54	Exhaust Stud Replacement? So TXpowersports will NOT warranty this part, even though the bike is 6 months old.. Hopefully I can extract my broken exhaust stud, but I really don't want this happen again. Can anyone recommend a replacement? I'm not sure where to start. I keep thinking about going to the hardware store, buying a steel threaded rod, and cutting it to length (and I'm sure the threads are metric). Should I order a new exhaust stud online? If so what is the best option?
	0

11-13-2018, 10:24 AM	#2
ChrisWNY Join Date: Jul 2018 Posts: 212	Are you referring to the exhaust mount that is in the lower-middle part of the frame or the the one that holds the muffler in place? Unfortunately TX power sports won't take any responsibility for anything beyond shipping...once you receive your Hawk, you're more or less on your own. That's the one downside of owning a China bike...warranty's are nonexistent. If it's just an exhaust mount, it should be fairly inexpensive to have a new one welded on or use a clamp instead (depending on where it is). __________________ 2018 RPS Hawk 250cc Mods so far: 1. Mikuni VM26 Carburetor w/#115 main jet 2. 17T/45T JT sprockets 3. JT 428 X-ring chain 4. Air box mod 5. Hawk Digital Cluster 6. Aftermarket IMS shift lever 7. Performance Aftermarket Exhaust 8. 295mm Nitrogen Gas Monoshock, 20W oil front forks
	0

11-13-2018, 10:31 AM	#3
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,717	You can pick up a new stud from your local auto parts. You can remove the broken stud by drilling it and use an easy out. This is what I use to remove broken studs on my truck. works great. https://www.lowes.com/pd/SpeedOut-8-...tor/1000170531 __________________ 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
	1

11-13-2018, 12:22 PM	#5
Red Hawk Join Date: Jul 2018 Location: NEPA Posts: 273	I would strongly caution you to use a milling machine to remove the stud. It would be a 4-5 minute job tops VS a trashed head. You must pull the head to do this. I just pulled 8 studs on my 53 year old tractor head. They were all to hard to drill on an uneven broken stud. After the 2nd stud let go at 12Ft Lbs on the torque wrench I'd made up my mind. Replace the stud with a good quality part, not an Ebay Far East one. If this job goes sideways a time cert sleeve can still save it if the drill walks off. Pm me if you want to use my mill. __________________ 2018 Hawk P&P Decked .040 off the head. 17/43 D.I.D. 428, NGK Iridium plug, DeCat, Wrapped pipe, Custom S.S. Muffler core, Nibbi PE30 115/35, L.E.D. Lights, Digital Cluster, USB port, Cutting Bord skid plate, Oil cooler w/ custom CRF oil filter inline, 5Wt fork oil, Rear Shock, CNC Back Rack, 30mm FAT bars, Bark Busters, ProGrips, Adjustable levers, Shinko 700’s lots of Loctite!
	0

11-13-2018, 12:33 PM	#6
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,717	If all else fails you can do what zippy did. http://chinariders.net/showpost.php?...&postcount=144 __________________ 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
	1

11-13-2018, 10:47 AM	#4
davisbm2 Join Date: Apr 2018 Posts: 54	Yep, I'm starting to see that with TX Powersports. Would you guys consider an exhaust stud as an engine component? I argue yes because it literally comes from within the head and without it the engine will not operate correctly... But I suppose I could see as a non-engine part like a turn signal but that seems doubtful. So just bring my good stud to Autozone and have them get a direct replacement? I bought some stepped left hand drill bits, hopefully if I work slowly and carefully they should work.
	0

11-13-2018, 02:21 PM	#7
davisbm2 Join Date: Apr 2018 Posts: 54	Thanks for the advice here is my game plan: 1. Drill out the stud using left handed bits 2. If that fails, try to retap the hole to a bigger size using a mill/ press 3. If that fails, drill new holes like zippy using a mill/ press 4. If that fails, sell the bike for like $600 and save up for a 10 year old Japanese Dual Sport 5. If that fails, give up on motorcycles and find a new hobby. Maybe whittling.
	3

11-13-2018, 05:28 PM	#9
llr Join Date: Jun 2018 Location: Dayton OH Posts: 17	Left handed bits are a start but you will probably need an easy out too.
	0

11-14-2018, 12:32 PM	#10
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	I've had the best success with left handed bits by first drilling a small pilot hole using a conventional bit. The left hand bit then just follows the pilot, hogs out a bit of material and hopefully backs the stud right out. __________________ 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
	0

11-14-2018, 06:02 PM	#11
Cravin01 Join Date: Jan 2018 Location: Forney Texas Posts: 498	Sounds like a good game plan, Also.. Tell yourself you gotta go slow, it could take a long time, and my not work out all that well. That keeps my temperature down when it goes slow, takes a long time and doesn't work out that well. anything other than that is a win. when you manage to get it fixed you can still whittle on your free time. Good luck brother! __________________ Visit me on YouTube at "Project Next"! https://www.youtube.com/channel/UC6KTCi2GVbfRDv-2XCqHhsg?view_as=subscriber 2017 Bashan Storm Keihen PZ30 Pumper Carb,115 main jet,35 pilot jet, gutted factory exhaust, Sambo Digital Speedometer,LED blinkers, H4 headlight,D.I.D X-ring chain 428,17/42 sprockets,UNI cone filter.
	1

11-16-2018, 01:19 AM	#13
Chinabike Join Date: Jan 2018 Posts: 361	found it better just buying a new head
	0