Exhaust Stud Broken

[miatamarty]

On the front head the top stud broke off flush with cyl head. At least it's sort of accessible. I was looking Summit Racing for replacement studs was somewhat baffled as to the size and thread pitch that I'll need. If worse comes to worse is there enough extra metal in the head to go up one size in diameter?

 

[Barrett]

Do NOT use anything other than the OEM studs.
Infinite amount in dealer system.....part # 16715-83............most all dealers stock them....list is $4.65 each
Sufficient material to go up one size but NOT necessary. Link below excellent and will walk you thru it.
Must be thoroughly soaked with PB Blaster or Kroil. Just a very loose fit from the factory and come out easily.

https://www.buellxb.com/forum/showthread.php?31106-Need-help-with-broken-exhaust-stud/page3

 

[miatamarty]

Thanks Barrett. It's a 65 mile ride to the Harley dealer but it's a great road to get there. I'm a long ways from nothing.

 

[Barrett]

Yes Sir my pleasure. The only comparable substitute I've ever found and used, if you choose that route, is Colony Hardware stud replacement kit......part # 2188-4. Zinc plated...complete kit...top quality...very reasonably priced and readily available online.

Typically the reason front exhaust port mounting studs break is a failure at the front muffler mount to include:
broken mount
snapped mount-to-case bolt
loose mount-to-case bolt
broken muffler strap
worn or missing mount swivel bushings
CHECK ALL OF THE ABOVE CAREFULLY

 

[miatamarty]

That part number didn't work on their website. Couldn't find any relevant listings for studs. Oh well, good excuse for ride to dealer.

 

[Barrett]

That part number didn't work on their website. Couldn't find any relevant listings for studs. Oh well, good excuse for ride to dealer.

https://www.ebay.com/itm/1754638991...SlVupfXGpA6tQf0gJOmir+nlQ5|tkp:Bk9SR5y7nMWMZA

 

[miatamarty]

Just ordered a set. Yet again, Thanks Barrett

 

[motoguy]

Yes Sir my pleasure. The only comparable substitute I've ever found and used, if you choose that route, is Colony Hardware stud replacement kit......part # 2188-4. Zinc plated...complete kit...top quality...very reasonably priced and readily available online.

Typically the reason front exhaust port mounting studs break is a failure at the front muffler mount to include:
broken mount
snapped mount-to-case bolt
loose mount-to-case bolt
broken muffler strap
worn or missing mount swivel bushings
CHECK ALL OF THE ABOVE CAREFULLY

Thanks for the info Barrett. After pulling my exhaust I found the front strap had been replaced by a big worm-drive hose clamp, and the bushings were loose / wobbly in the front mount. Sounds like that's what snapped the rear stud. Thanks partially to your info, I'll be purchasing some replacement bushings when I get it reassembled. My goal is not only to repair the damaged part, but to prevent it from happening again!

 

[Barrett]

Yes Sir my pleasure. I have always had a moderate disdain for the factory XB exhaust systems but live with them. If you think about the total weight of the header and, for example, an XB12 muffler with power valve, there is a hell of a lot of girth hanging off the bottom of the engine secured by only 4 straps around 2 fairly small mounting points. Everything and I mean everything must be installed correctly...all hardware properly secured and torqued...and all parts OEM or the inevitable outcome is broken exhaust port studs which are a huge PITA to remove and replace.

 

[motoguy]

Yes Sir my pleasure. I have always had a moderate disdain for the factory XB exhaust systems but live with them. If you think about the total weight of the header and, for example, an XB12 muffler with power valve, there is a hell of a lot of girth hanging off the bottom of the engine secured by only 4 straps around 2 fairly small mounting points. Everything and I mean everything must be installed correctly...all hardware properly secured and torqued...and all parts OEM or the inevitable outcome is broken exhaust port studs which are a huge PITA to remove and replace.

Any suggestions on ways to bolster the factory mount situation? There's only so much room for straps...I am making sure to use a factory strap to replace the worm gear hose clamp.

I also have a question on the bushings for the front mount. I'm curious how to tell when they're "too worn". The bushings I took out were fairly loose / wobbly, but checking some of my other bikes they have a little bit of play as well. I assume they're not supposed to be so tight they're a friction / interference fit? I'm not sure of Harley pricing / availability, but Aasgaard offers replacements for $10/side. Easy and cheap enough to consider a wear item if necessary. He's OOS at this time though. I've not looked for replacements from other sources. As simple as they appear to be I imagine they can be found elsewhere as well.

 

[BuddyB]

Well, as far as the studs, just get' em from ST Paul or what I did was from my local HD dealer. If you are asking about the front Idolator, the rubber one, there are all kind of posts about that. The studs hold just fine.

 

[BuddyB]

I mean front Isolation mount. I don't idolize my mounts. Though when you ride a Buell, it might be a good idea.