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Mine broke off from the head thats being cleaned.

www.z1enterprises.com/exhaust-stud-6x27-kawasaki.html

A set of stainless studs and nuts.

z-fever.de/shop/de/product_info.php?info...n-edelstahl-6mm.html



If all went to worst case cenario, a M8 to M6 stud

z-fever.de/shop/de/product_info.php?info...ehbolzen-8-6-mm.html

A lot of head to the alumium is your friend to remove studs!!!

 

At work i would drill a hole (1/16 to a 1/8 )all the though the stud,lay a flat washer then a 8mm nut,then use a wire welder and weld through your hole up to the nut ,let it cool then twist it out , it it breaks do it again.

Use caution when joining stainless steel and aluminum due to galvanic corrosion. Probably would be ok with exhaust studs but definitely use some anti-sieze. 

urankjj wrote:

Use caution when joining stainless steel and aluminum due to galvanic corrosion. Probably would be ok with exhaust studs but definitely use some anti-sieze. 
 

Whats a good way to get the old studs out? I dont want to break them off either.

So more the differnce between a precious metal (Stainless steel) and un-precious metal (Aluminum), a galvanic reaction (oxidation) between the metalls can occours. A anti-sieze is nessesary to build up a insulate galvanic boarder line. Thanks  urankjj  for the hint.
 

I would saturate them with a penetrating solvent, (Kroil, Superzilla, or something similar). Let sit for at least 48 hours then remove. Good luck always.

I use a DeWalt 1/4" impact to remove small bolts and studs. It's really not powerful enough to break them off. But the impact, patience and Kroil will usually prevail. Using heat before attempting to remove the studs will prevent most of the breakage.

If the exhaust studs are not bent, and the threads are in good shape and not stripped. I would leave them alone!!!
I have motors that are 40 years old with the original exhaust studs without any problems!!!

If it ain't broke, just leave it alone!!         Why risk breaking off a stud just because you wanted new studs.
 

MDM is to only 100% sure way. Search it up. You might find someone close and not have to deal with it, otherwise welding a washer then a nut to the washer is my next best option. Drilling it out till you get to the limits of the threads then collapsing the remaining bolt in towards the hole , last I cringe to even suggest is an easy-out, to drill it out big enough to get an easy-out to work, you would be increasing the friction between the hole and the bolt. Beyond the MDM, any other method needs to have the first step, be soaking in a good capillary deep creep penetrate oil, with some heat and cool cycles. Good sharp taps with a punch on the broken stud will help, but don’t use a pointed punch, again like the easy-out you will be forcing material outwards and increasing friction. Good luck. 

Is that the same as EDM
Which I have had done on my block to remove a couple busted off studs and bolts
DD