I introduced myself to my neighbor across the street who has an XR500, couple harleys and he's got it all.. i'm gonna give it a shot. let you know how it goes

 

This suspense is terrible. I hope it will last.

 

if you've taken a look at your header before, you can see it's impossible to fit a threader in there. I sawed it short past the stripped threads and filed it. and still have extra left past the nut.

 

i should've left this topic and never came back!!!

 

sooooo........ what does a new head cost? lol

 

Hey Whip, post up a pic of the stud you want to extract. (Yes; I know what they look like. I want to SEE yours; I want to see the condition of the stud before I suggest putting heat on it and twisting it off.) Assuming it has decent "integrity," (Lotrat's) suggestion of penetrant/heat/easy-out is the way to go.

 

OK, joking aside. Ill post up some actual knowledge of that exact stud. I knew i had a bent stud before i did my 351 kit. So when i did the big bore i bought two new studs and was going to replace them both. Well, even with the head off i had a hell of a time getting it out. PB blaster for days, acetylene torch, and vise grips as tight as i could make them. No go. My one riding buddy is a machinist on the side. So i paid him a visit. All he did was screw a nut onto the stud, there was some good threads at the end, and just keep screwing it on until i got bound up in the smashed threads, then he really cranked on it and with out any heat, after the nut was good and jammed on the stud, turning it the opposite way it just backed right out. No problem. I was very relieved that the head wasnt messed up. So i thought since i bought both new studs might as well change the other. So we just put 2 nuts on the other stud and tightened them against each other and used that to back that stud out. So dont be surprised if heat doesnt work to get it out.

 

Since space is tight, start threading a 6mm nut on the broken /stripped stud. Get a mig welder and start welding to the stud filling in the threads inside the nut. The heat will help when unthreading the old stud , install the new one while head is still warm. Simple & quick

 

after taking a long look at my header bolts...(i used a socket wrench with a straight long extension to access it when installing the megabomb)....i was going to say just tap it with pointed chisel or similar...long carbide tip drill to drill the center of the stripped bolt....smaller reverse threaded bolt...hope the small bolt head can handle the torque...

i do apologize to whip-n-dip for the earlier comments.....hope you resolved this issue...

 

(Hey, he doesn't warranty his advice......don't trust him!)

Yes, yes; just kidding. ahnh has some great chops.