Just wanted to share the state of my 09. Since I've owned the bike this is the second time my header nuts have come loose. Except this time the stud broke off. The harley dealer says all the gaskets and o rings are in stock but if they can't drill out the stud then I'm SOL. I'm considering taking the bike to a well known engine shop called Hillside motorcycles and machine in upstate NY.
CITGO
Broken exhaust stud
Just wanted to share the state of my 09. Since I've owned the bike this is the second time my header nuts have come loose. Except this time the stud broke off. The harley dealer says all the gaskets and o rings are in stock but if they can't drill out the stud then I'm SOL. I'm considering taking the bike to a well known engine shop called Hillside motorcycles and machine in upstate NY.
Attachments
Do a search for 'broken stud' in the search bar, you'll find quite a few threads were other owners have had similar problems and some novel solutions.
I personally have welded a nut on brake disc studs and got them out that way, either way good luck 👍
I personally have welded a nut on brake disc studs and got them out that way, either way good luck 👍
I had a friend with a Softail Deluxe who was getting V & H long shots put on at a HD dealer. This is what happened to them when they removed the old exhaust., They ended up having to take the head off to get that out. At least consult the machine shop to review there plan of action before making your mind up. I dont think drilling it out is an option as EZ Outs are not going to budge that
Wow is this ever timely.
I refitted my Bassani earlier this summer because it looked like the previous owner didn't know how to install an exhaust (spoiler alert: I've done more than a few exhausts in my years). Two weekends ago the forward header came completely detached and the aft flange wasn't far behind. Besides losing both fasteners, she completely spit the forward gasket out. Thank God it didn't shear a stud, however the silencer did chew the sh#t out of my swingarm. Pissed. Next time I'm using locking hardware.
So sorry to hear what happened to your bike. Hopefully the broken piece comes out without too much drama.
I refitted my Bassani earlier this summer because it looked like the previous owner didn't know how to install an exhaust (spoiler alert: I've done more than a few exhausts in my years). Two weekends ago the forward header came completely detached and the aft flange wasn't far behind. Besides losing both fasteners, she completely spit the forward gasket out. Thank God it didn't shear a stud, however the silencer did chew the sh#t out of my swingarm. Pissed. Next time I'm using locking hardware.
So sorry to hear what happened to your bike. Hopefully the broken piece comes out without too much drama.
Drilling the stud is the most conventional fix. There is a jig available to drill Harley exhaust studs.
Check this thread, it might be helpful
www.xr1200ownersgroup.com
the jig that Phaedrus mentioned is linked there
Regards
Roy
Exhaust Studs
I know there are a number of threads on here about the exhaust studs breaking...I am now in the same boat. Anyone have recommendations on how to get these out without having to disassemble the engine?
www.xr1200ownersgroup.com
the jig that Phaedrus mentioned is linked there
Regards
Roy
I've seen more and youtube mechanics (take it for what it's worth) welding a nut on broken exhaust manifold studs on vehicles and turning them right out. Even aluminum heads. If I were to bust one of these fellas, I'd pick up a cheap MIG and give it a shot... (I've done the drilling and easy-out thing in the distant past and just for me, I am far too clumsy or unskilled for detailed work like that).
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
