TexasSportBiker
Member
- Joined
- Jul 16, 2009
- Messages
- 22
2009 XB12R here. Around 20K miles, I notice an exhaust leak developing from the front cylinder. Discover that the one of the header nuts is missing, and the other is walking it's self off. Since I was at the dealer, and it was cheap, I just had them replace the nut and re-torque it down.
Less than 60 days later, the problem had returned. This time, both nuts were missing along with snapping one of the studs off. Decided to do it myself this time, with the help of a neighbor, that is an accomplished mechanic/ machinist, welder. We welded a nut on to the snapped stud, removed and replaced it. All well for another 1000K.
Then things start turning UGLY. Am hearing that at certain RPMs a rush/seeping of a leak again, but my collar nuts are still secure. A much closer inspection has revealed several hairline cracks developing on the front header tube just before and aft of the bend. No big deal right? Am guessing it was caused back down the road somewhere when the front tube was loose, and the vibration stress causing.
Back to see my friend. Did a real nice job of TIG welding it up. 600 miles later, it's back. Further inspection on the backside of the tube shows multiple spider webbing of cracking occurring. Re-welded them up again. At this point it's looking ugly on the backside. 400 miles later, it's back. I check the nuts again and see that they are starting to "walk off" again. Re- torque. 100 miles later a new hairline crack appears. WTF!!!! Is going on here??
I am resolved now to just repalce the header. $245 from my once local Buell Dealer. And was quoted about $400 for the install. Am mechanically inclined enough to do this myself without the "engine rotation" as posted up in another thread. (That is a God send!)
Questions: Is this a common problem with the front studs/nuts/collar??
What can I do to keep it from happening again once I have repaired it??
Many Thanks!!
Less than 60 days later, the problem had returned. This time, both nuts were missing along with snapping one of the studs off. Decided to do it myself this time, with the help of a neighbor, that is an accomplished mechanic/ machinist, welder. We welded a nut on to the snapped stud, removed and replaced it. All well for another 1000K.
Then things start turning UGLY. Am hearing that at certain RPMs a rush/seeping of a leak again, but my collar nuts are still secure. A much closer inspection has revealed several hairline cracks developing on the front header tube just before and aft of the bend. No big deal right? Am guessing it was caused back down the road somewhere when the front tube was loose, and the vibration stress causing.
Back to see my friend. Did a real nice job of TIG welding it up. 600 miles later, it's back. Further inspection on the backside of the tube shows multiple spider webbing of cracking occurring. Re-welded them up again. At this point it's looking ugly on the backside. 400 miles later, it's back. I check the nuts again and see that they are starting to "walk off" again. Re- torque. 100 miles later a new hairline crack appears. WTF!!!! Is going on here??
I am resolved now to just repalce the header. $245 from my once local Buell Dealer. And was quoted about $400 for the install. Am mechanically inclined enough to do this myself without the "engine rotation" as posted up in another thread. (That is a God send!)
Questions: Is this a common problem with the front studs/nuts/collar??
What can I do to keep it from happening again once I have repaired it??
Many Thanks!!
