Thought I'd spruce up my 1993 XR650L by putting an FCR-41 carb and an FMF Powerbomb and Q2 can...Went to work on taking off the stock header and thought I'd soak the rusted nuts and studs with PB and take a few days to slowly work off the nuts and/or the studs. Well I managed to get one stud to come out with the nut frozen onto it:applause: , one nut off:applause: , and the other two studs snapped off:banghead: , leaving about 1/2 inch exposed. So then I sprayed more PB and put two nuts on the stud that allowed the its nut to come off and tried to back out the stud:busted: ...I snapped that stud too:foul: . Then I called my local Honda repair guy and he said I should have cut the nuts off with a Dremel, leaving the studs intact:prof: ...brilliant! I somehow had the idea that it would be a good idea to replace the studs, seeing how rusted they were. I've since drilled out two of the studs and tried an EZ-out, which snapped inside one of the studs:censored: ... none of my drill bits would even scratch the shorn-off EZ-out. Luckily, I could Dremel-cut the stud back to the cylinder housing at which time the EZ-out fell out:applause: ...none of the studs would respond to the EZ-out:mad: . This still leaves the one stud which I can't get to because it's too close to the centerline of the bike and the frame downtube is in the way of my drill:crazy: . Okay, the long and short of this meanderance is that I will probably have to take the motor out of the frame:cry: and take it up to Eureka to have some engineering outfit laser the studs out. What was supposed to be a fun-filled Saturday fitting my new FMF powerbomb and Q2 and Keihin FCR-41 has quickly turned into a week of frustration and who knows what the laser guys are going to charge me for cleaning out the stud holes. I'm not the type that gets silly frustrated...I consider all the above as lessons learned. Can't wait to get it all running again so I can go riding!