Exhaust Header Stud broken at manifold

I was wondering if this has happened to anyone else - what sounded like an exhaust leak turned out to be a big one! Left hand header, the outer stud has sheared at the manifold and broken off, taking the bolt with it. The other stud/bolt is still in place, and the header has twisted around its axis about 5mm. The problem of course, is that half the stud is well buried in the outlet. The bike is with Motociclo in Sydney - way beyond my meagre allotment of mechanical skill.
Now - I didn't drop the bike, and nothing external has put any pressure on the pipe... a mystery, or is it more common than I think?

Can't think it's common. The only one I've ever seen bust was one on my own bike. Yes, I felt like a complete goose!

Whenever I get something shit like this I just call up Capital Thread Repair, a mob who specialise in removing broken shit. Saves taking the head off but even that is only a half hour job.

Pete

Thanks Pete.

The last time i took my headers off i snapped two of them off!!!! and i thought i as carefull. luckily there was enough thread to get some nuts back on and I have ordered some replacements, but like you i am not happy to have a go at replacng them, as they may break off flush and then a distinct lack of happyness will pervade the garage. So next service, i will get the garage to do it :-)

sidrat wrote:

The last time i took my headers off i snapped two of them off!!!! and i thought i as carefull. luckily there was enough thread to get some nuts back on and I have ordered some replacements, but like you i am not happy to have a go at replacng them, as they may break off flush and then a distinct lack of happyness will pervade the garage. So next service, i will get the garage to do it :-)

Yep. The stud has broken off flush, or a few mm's inside the head. This didn't happen while removing the header though - it happened while riding.

Somebody somewhere will have a drill jig for these - with a good extractory and bit of heat they will come out quite easy but to save the pain get someone in and remove all 4 then replace with factory items.
The nuts are easy to get at so remove and copperslip once a year. Don't over tighten. They will have a low cold torque setting around 15-18 lb/ft.

Brass nuts, neverseez, Bob's ya uncle!

If you have a steady hand, you can drill them out. Mark the center, and start with a 3 mm new drill, get that hole in the center. After that each time a bigger one.

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But with the head I had the same, someone put a stainless steel stud in. But that one was enough outside that a grip could get it out.

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Go to "Wot a lota crap" or your favourite auto/tool store and buy a set of easyouts. They generally come with a drill that matches the extractor.

Oh and don't use the extractor in a drill like a bloke did here at work - extractor snapped off in the hole - got pretty messy after that!

These are hand tools not power tools - gently, gently is the way to proceed.

Thanks all - they fixed it at Motociclo, as I reckoned they would.
Apart from Pete though, no one has picked up the reason for my post... the stud sheared right out of the blue, as I was riding... WTF?
I wasn't working on the headers, hadn't dropped it, wasn't even looking at it. Heard a noise and ... header falling off. OK - only makes me love the Guzzi more, its not a Honda.
Glad it didn't happen on the Tasmania trip I just got back from...
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...just picked the bike up from Motociclo. Have to say, those guys are incredible - the heart of Moto Guzzi in Sydney, I'd say.

I have a lot of time for John's shop. Believe me, that's a big compliment.

Pete

Totally. Motociclo stand by the bikes they sell.

peterc9 wrote:

Totally. Motociclo stand by the bikes they sell.

unlike others...

The old guy down the street taught me to use three reverse thread drill bits. Mark with a punch and start with the smallest with plenty of penetrant for lubrication. The medium bit usually has the stud spinning out.

peterc9 wrote:

...just picked the bike up from Motociclo. Have to say, those guys are incredible - the heart of Moto Guzzi in Sydney, I'd say.

One went last year same as yours, just riding. Wasn't too difficult getting it out. extractor and heat gun.

As to it snapping, my money is on a combination of corrosion and high revs.

Probably the most mistreated GRiSO ever that lives leaned up against the wall of my office, out in the weather. If a storm is coming I might chuck a tarp over it. Sun is making the dash white. Running great at 50,000.

GRiSO abuse, bad karma!

A little late to the party, I noticed the right cylinder sounded a little exhaust leaky. Grabbed a wrench to see if the gasket had gone AWOL like one of the gaskets on the Y-pipe did (owned the bike since new no one has touched it but me and one of the gaskets was not there) and what do I find? Nothing! Stud broken off just below the surface.
I'm just a little bugged about it. I've never been able to get a stub out without doing more damage to the offending hole. Might actually take it somewhere. That from a guy with mechanics on all sides of the family.

Build up the broken stud with tack welds till you can weld a nut on it.

This happened to me on day 2 of my cross country trip--- Luckily hotel I was staying at had an advance auto and I had *Just* enough thread to screw a nut on and loctite it-

I will have to solve this problem in a few weeks when the bike gets shipped back- Figure I'll try the ole vice grips first-

Is this header bolt a replacement part?

It's a common 8x1.25 stud.