Well two types of stud extractor, a welded nut, that snapped the stud flush with the head, drilling and tapping on a slightly off angle and 2mm drilled out of the front flange and......... my buell is back together . It has been a massive headache but I have gained some valuable experience (not to bother and get sum1 else to do it for ya ). I am pleased to say though that it fired up first time and no engine light was on, still need to check for leaks thoroughly around headers but a quick test with toilet paper didnt show anything obvious. So I am just praying that all is well now!!!!

For future reference, when buying stud extractors, buy the cheapest ones you can find, then throw them straight in the bin. It will save you a few hours and a lot of heartache.

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I started out with nothing and still got most of it left.

.......unless they're Snap-On splined extractors

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Mithered ta death.
92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR

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2001 X1 2009 1125CR 2006 Uly X3 2010 Uly a fully Maz'd S1 and a 1991 RS1200 Westwind.

x2

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If your dreams don't scare you, they are not big enough.

Prevention is better than cure.

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08 Specialized Langster

I drilled mine out with carbide drill bits and then tapped the head M8 and replaced the studs with socket head cap screws. Only the front ones were problematic rear were fine. Fitting new gaskets was a pain in the arse. Anyone know any tricks for fitting these

I make sure the recess is clean first, scrape out all the aluminium oxide and crap, then Copaslip the bore and then work the gasket in, little by little, around the circumference.

Preparation and patience do the trick...

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08 Specialized Langster

Remember that one reason that studs are used and not bolts is to prevent wear in the threads in the aluminium by repeated removal from the head..

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2001 X1 2009 1125CR 2006 Uly X3 2010 Uly a fully Maz'd S1 and a 1991 RS1200 Westwind.

How many times will the headers be removed in the life of the bike? More times than the inspection cover for the primary chain?

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08 Specialized Langster

Liberal application of copaslip cuts down on the wear and tear.