Before you go out and buy a welder, one last thing you could try is grinding a flat on opposing sides of the stud so you can get a spanner or pair of grips on it securely.

Just tried this but I can't get the two bolts off that I've used to strip the thread from the stud.

I've just ordered an arc welder which I'll be picking up tomorrow morning. Hopefully the extreme heat may break the seal.

I'm assuming I need to remove anything electrical from the bike as I'll be welding a nut onto a stud still attached to the engine. If anyone knows exactly what I should remove and also where I should be attaching the earth clamp to, I would greatly appreciate any advice/tips.

I've never welded before so I'll be practising on the 3 studs I've removed before I chance it with the stuck stud!

Hi Arn

You need to disconnect the battery and the CDI box welding the nut on will not generate enough heat and you need put a lot more heat on the stud at the cylinder end because if you shear that off then you will be in the doo doo.

Finally! After nearly a month of trying to remove one bolt I manged to get it loose yesterday. My theory was sound but I was let down by my application. (Lets just say welding won't be making it onto my CV!)

I went through around 15 - 20 nuts trying to weld one successfully enough to the stud to get enough purchase to remove it. I'm sure the constant heating and cooling cycle helped in the end.

The really frustrating thing was that it only took me about 45 minutes to fit the new system. Fired it up yesterday, no leaks! :toothy9:

All in all a very positive experience! The bike looks and sounds miles better, saved some weight, gained some ground clearance, learnt some new skills and bought some new tools.

Once I've cleaned it up and put all the other bits and bobs back on I'll post some pics.

Thanks angain for the help chaps.

:toot: Well done - got there in the end!

As you say, not only have you got a better bike as a result of your blood, sweat and tears, but you've learnt a lot from it too. So what's the next mod then? ;)

Definitely a bash plate, either MM or Adventure Spec (modded slightly to fit the R). I'll be ordering it as soon as I can make my mind up.

I'm leaning more towards the Adventure Spec as it looks like it offers much more protection, although it's expensive and heavy.

Surely not the MM one for the Tenere? IMVHO, it is possibly the most horrible looking and made accessory I've ever seen created for an XT! ;)

The one for the XTR doesn't look a whole heap better either!

Just had to do a quick search for the MM Tenere bashplate... WOW! Did they make it out of Meccano?

I was looking at the MM XTR bashplate. Yer, I agree. It isn't the prettiest but like I said, it's cheap and probably a lot lighter.

I have an XTR, only looking at the Adventure Spec Tenere bashplate as they don't seem to make one for the R. There is a review from someone who's fitted it to a R with a "small modification." He's added links to some pics. Looks very nice and very substantial!

I must admit, I'd probably go for the Adventure Spec option, if nothing else because of the aesthetics. There are indeed a couple of members who've successfully adapted it to go on the R and it looks really rather good. I can see why cost would come into the equation though.

Meccano is a good description of the MM Tenere bash plate! :rotf[1]:

Well done Arn in getting the pipe on at the first attempt even when I did it on the second I can remember ' Blimey this could be a drawn out affair' and I thought I was lucky.

And for some strange reason I thought you had an X when we were talking so I feel happier because while I think the 2 into 1 is the way to for the R it wasn't where I wanted to go with my X.