Broken Exhaust Stud on KZ440LTD That I Cannot Get Out

Left side outer exhaust stud broke off flush/just a little bit recessed on my KZ440LTD and it is whooping my ass hard guys. I tried to shock it out with a hammer and punch to no avail, let in soak in PB Blaster for 3 days before using an EZ-Out, it broke off inside the stud (rest of the EZ-Outs were promptly thrown in the garbage). I tried welding a washer and nut to the end but it would twist off as soon as I put any amount of torque on the bolt. At this point I'm not sure what to do besides taking the head off (which worries me because I'll probably mess something else up as I tend to do) and getting it drilled out or buying a replacement head for possibly the same cost or cheaper and installing it. Thank you all for the help and sagedom, I'm still learning and do not want to make this mistake twice.

Experience is a very good, although sometimes costly teacher. 

Good luck with your endeavor!

Mike

wrote:

Left side outer exhaust stud broke off flush/just a little bit recessed on my KZ440LTD and it is whooping my ass hard guys. I tried to shock it out with a hammer and punch to no avail, let in soak in PB Blaster for 3 days before using an EZ-Out, it broke off inside the stud (rest of the EZ-Outs were promptly thrown in the garbage). I tried welding a washer and nut to the end but it would twist off as soon as I put any amount of torque on the bolt. At this point I'm not sure what to do besides taking the head off (which worries me because I'll probably mess something else up as I tend to do) and getting it drilled out or buying a replacement head for possibly the same cost or cheaper and installing it. Thank you all for the help and sagedom, I'm still learning and do not want to make this mistake twice.

You will have to remove the head, then look up EDM bolt removal in your area. This process will remove the broken easy out and the remains of the bolt for approx $40