Question about BMW R 1150 GS Motorcycles

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While replacing the exhaust studs on my BMW R1100S i had successfully drilled out and retapped 3 of the studs but while attempting the 4th one which had sheared off below the surface I managed to break the drill off inside the stud. The drill bit wont come out, is there any method of getting the drill bit/stud out that I can do myself. All suggestions welcome, thanks

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You were probably using something like a 1/8 drill, which means that the flutes are pretty small and cannot get anything down them to try twist the drill piece out. Try loosening the bit by tapping it with a small punch and hammer, if you are lucky you might just free it enough to work it out. (If it were a perfect world you would be able to drill from the other side and tap the bit out from there). The only other alternative for you to try is to try burn it out with an acid. The most effective one is Nitric acid, but I doubt you will be able to get any of that, it is a controlled substance. Hydrochloric acid will work as well but will be a lot slower. Build a little trough around the broken stud hole using Prestick or kids play clay, pour the acid into the trough and let it do its work. The acid will be come depleted and need to be refilled often and you will of course need to take all the precautions to protect your eyes and bare skin. If that does not work you will need to find an engineering works that has a spark erosion machine or something similar and take the cylinder to them to remove the part.

Posted on Mar 17, 2011

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