Modern Vespa

My exhaust has been the only problem with my 15k + GT200. I have had to replace the graphite spacer/stupid design/bearing with a moto amore brass one. A good idea for anyone. I have had to have the pipe re-welded on a road trip and now it has seemed to snap an exhaust stud. of course the parts book tells you its a stud but thats about all, no size. Anyone know off hand what size it is?



Nitro

Just take one of the nuts for reference. As far as length I assume you will have to drill it out right? I dont think exact lenght will be an issue as long as its long enough you can cut it down as desired later.

Good luck, thats a bummer

Had the same problem. Mine couldn't be extracted so I had to replace the entire head. I feel your pain!

I broke one too and could not remove it on my GT. My local service shop removed the engine and worked on the stud on the bench and finally did get it out after twisting the heck out of the easy out.

The stud is a odd size- 7mm. Maybe you can weld a nut on to it and back it out if there is still some of the stud showing.

Good luck

Peter

The lower exhaust stud broke off on my ET4 and couldn't be removed.
The bolt retractor even snapped off.

I ended up drilling and tapping a smaller hole for a smaller diameter bolt.
Not the best solution, but the best I could come up with.

Sorta sucks.

Better than buying a new head

Usually when the ezout breaks off, its game over in my experience. Unless someone knows a trick I would love to know

Word. That seems to be the case. I made some inquiries at local shops and machinists about having a bolt removed with a snapped retractor inside. The responses can be filtered down into two words: "You're screwed."

I sure there is something out there, but right now I just hope that the other bolt doesn't break, too.

Menhir wrote:

>I sure there is something out there, but right now I just hope that the >other bolt doesn't break,


Hi all,

I've been lurking the past 2 weeks, read only. I have a new scooter on the way (GT200), and was researching info about it on this site. I was going to formally intoduce myself in a week or so when I have more spare time, but I have some info on this subject and wanted to contribute.

There is a process for removing broken drill bits, easy outs, etc... Goes by the name EDM, Electrical Discharge Machining. If there is one in your area, they *might* be able to do it. Safe bet to say the engine has to come out, maybe even the head off. Here's one link of a place that I have personally used. http://www.lcmiller.com/Services/services2.html

HTH

TonyM

the size is 7mm

first, the only right way do tackle the job is to remove the head. at minimum you should remove the motor. on the other hand, you could suspend the bike upside down and work on it...

if there's a tang still present, then you could heat harden the stud and then use a small punch and some vice grips to ease it out.

if it's flush or below the surface, you'll need to anneal it with a torch. drill it and then use an easyout with a ton of penetrant. hopefully you won't snap off the easyout...

personally, i'd just take it to a machine shop and have them use EDM to remove it. save yourself the headache and let the professionals deal with it.

best,
-greasy

There was very little outside the head I will post pics later. I could get vice grips on but there was not room to move them.


The solution
A snap on pro model blue point stud extractor. Picture a super hardened socket and the inside is like the relief of easy out. It grabs the stud when you turn it with a socket. Its expensive but its the right tool for job. There has to be something to grab for it work.

As for the replacement stud. I looked at all the cases I have. Vespa, lammy and small frame. The electric start studs on the P200 and prob a p150 but I can't confirm

Fit. It was a little long but and extra washer and voila.

15 mins with right tool, total f'ing nightmare without it


Thanks to Steve at Mr Moto in Chicago for loaning your tool


Nitro

I want to correct an error in above post. I used the stud from the shift box not the starter

Nitro