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Discussion Starter · #1 ·
Hi, I own a 2005 R6 and the exhaust flanges rusted clean through and the remaining studs are badly rusted and seized.
I used a stud extractor on the one good stud and it snapped at the head, i welded a nut on another and it snapped at the head, I tried drilling with a cobalt bit and it snapped in the stud. I am wondering should i call it quits and remove the engine as access to the studs is poor and may need to take it to a shop.
 

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Discussion Starter · #4 ·
Yeah they're the worst i've ever seen in 35 years of motorcycling. I'm going to pull the engine out as access is so difficult, phoned a engineering firm and they want to take the head off, but ill shop around for better ideas. I hope my bikini bottoms are clean when i get the bill. Anyway i'll try soaking and heating for a few days and try parrot-nosed pliers as you suggest, i may end up just having to drill them myself.
 

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Discussion Starter · #6 ·
I only have a plumbers torch , so I hope that won't heat too much, if I'd had oxyacetylene I'd have melded the block, such was my frustration. I've made the engine mount wind out tool and could only wind the sleeves out a couple of turns . My problem now is removing the engine , it looks like it will swing down quite a bit on its lower rear mount but how do I support it , or lift it to get it back in. Is there some sort of cradle /box design or am I over thinking it. I have a trolley jack and i think i can drop it onto its front then pull the lower rear bolt would this be the best way to do it.
 
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