HOW CAN I SAFELY REMOVE THE CYLINDER STUDS FROM MY DIRT BIKE

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HOW CAN I SAFELY REMOVE THE CYLINDER STUDS FROM MY DIRT BIKE?
The simple answer is there is no safe way that is 100% guaranteed not to break off a stud.
Sometimes they break and you have to drill them out.
With all that being said, there are some ways to remove the studs that will greatly increase your chances of removing the studs without having them break off.
One of your best friends is as shown below:



That's right, HEAT IS YOUR BEST FRIEND.
Many studs are held in with thread locker.
Unless you heat them first you will have a real hard time getting them loose.
Some studs are just plain stuck due to corrosion.
Your next best friend is shown below:



Get some good penetrating oil (We use Kroil) and let those studs soak over night.
We further suggest that you apply the penetrating oil several times during the day and then let it sit over night.
Sometimes it takes a combination of heat and penetrating oil to help them come out easier.

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So, you are all ready to twist those studs out, what can you use?
One of my least favorite methods is to use vice grips.
Sometimes they work, but most of the time the vice grips aren't strong enough to break the studs loose.



Another method is to use two nuts.
Screw two nuts down on the stud and tighten them together with two wrenches as shown below:



Once the nuts are tight to each other you can put a wrench on the bottom nut and attempt to remove the stud:

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If the nuts can't hold, you can use 3 nuts if the studs are long enough.
To use 3 nuts, screw on two nuts and tighten them together.
Next, screw on a third nut and then tighten it holding the top and bottom nuts with two wrenches:



Next, put your wrench on the bottom nut and try to loosen the stud again:

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If the nuts still won't hold, remove the nuts and re-install them using the same method above but this time use some thread locker to install the nut's.
You will have to allow the thread locker to dry before you try to remove the studs.



There are several different colors of thread locker available.
Each has a different temperature release point.
I typically use the red or orange but occasionally I have used green or blue which has a much lower temperature release point.
Once the thread locker has dried try to remove a stud.
If the stud still doesn't want to release, heat the cylinder around the base of the stud and try it again.
If this method has failed I would highly recommend my most favorite method.
This will cost you a bit more but gives you the highest chance of success.
There is the right tool for nearly every job and stud removal is no different.

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This is a 8mm stud removal tool.
Using it is very simple.
Slip the tool over the stud, attach a wrench and turn it.
The tool will slip a bit and then suddenly grip.
Don't loosen pressure on the tool as it will loose it's grip and you will have to start again.



If you are still having problems, soak the studs over night in penetrating oil, apply heat, and don't get in a hurry.



If you break off a stud it can be drilled and if necessary repaired and tapped to accept a new stud.
I hope you find this information helpful.
As always, if you have comments or suggestions, feel free to email me or post on the forum.
Thanks!
SB