HELP!!!!!!!!!! Exhaust Stud issue. (Missing bolt?)

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FlaXB9R

FlaXB9R

Well-known member
Joined
Oct 13, 2011
Messages
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Ok so the other day I had a CEL 13 trouble code (O2 Sensor) I started a thread the other day referring to it and had some help with that. I also read the trouble shooting in the service manual. Anyways I went out the other day to try and see how hard it would be to get to the O2 sensor and when grabbing the headers bending over I noticed a little movement. Not a lot of movement but I knew right away it wasn't right. Checked the front header and no movement.

I got off work early today and figured I ought to look into the issue. Assuming the worst (Broken Header Stud). Before I started tearing into her I shook the rear header again and I could hear something like it was grinding against threads. So I have it tore down and it seems to possibly (hopefully) just be missing a bolt. I have a few pics I going to post but my question is could this be a possibility that it is only missing a bolt and not a broken stud?

If you look at the pics I don't know if you can tell for sure but it looks as if the stud isn't sheared off, it looks fresh. Although there isn't any threads showing the bracket is tilted bad and looks that if I loosen the bolt that is there it would even out and have threads.

Any help will be greatly appreciated


IMAG0657.jpg


IMAG0658.jpg


IMAG0653_BURST006.jpg


IMAG0651.jpg
 
Is the exhaust gasket a hard fix? Rotate motor or can I get it from where I'm at?

Thanks for the help
 
With a 1/4 socket with a extension and swivel you can get that back bolt off from the bottom ( under the frame not through the hole for the fan)
But you will need to drop the exhaust and use heat to remove the front header bolts so you don't break them.


Or you can do a hack job it and remove the bolt, pick up two more from harley.
use a standard screw driver pry the exhaust flange back in place bolt it back up and live with a possible exhaust leak.
 
Or you can do a hack job it and remove the bolt, pick up two more from harley.
use a standard screw driver pry the exhaust flange back in place bolt it back up and live with a possible exhaust leak.
Click to expand...

Hack job [up]

If you have the time order the tapered exhaust gaskets, 4 studs/nuts from ASB. I cant stand the factory exhaust gaskets they make it a pain in the ass!!!
 
im not sure id try and remove the stud, if you break it off its going to be a bitch. just put some anti seize on the new nut and call it good if the threads arent damaged.

new gasket for sure though.
 
Thanks for all the help.


Heading to Seminole Harley now to get gaskets retaining rings and nuts. I was very tempted to do the hack job. I soaked the header bolts with pb blaster and checked about an hour later and they came loose with little effort[up]. Called Harley and everything is in stock so I'd be an idiot not to take care of it now.
 
Ok so what's the trick of getting the headers out once everything is took apart? The video didn't explain that and it actually looked like he did it one handed and it ain't happening for me with two.
 
That video at the end, his just popped off no twist!?! Wtf!?

Onve its all loose including the front subframe, pull the front tube down and out. From there youll twist the whole assembly up and back with a little rocking while watching the rear flange. Once almost upside down should slip out.
 
whether you pull the rear shock and fan, or rotate the engine...if you get the oem type exhaust gaskets, a lil trick i learned that makes them a lot easier to put in (which still takes a lil patience) is Put them in the freezer and when your ready, swipe a coat of anti-seize on the outside and they go in much easier. Basically you get it started in the port and keep going around and pushing it in gently. Maybe have to use I small flat screw driver to help push in the edge to get it started in the port, the last thing you want to do is puncture the new gasket or crush the side with too much pushing force. It has been mentioned in a few threads I've read that the flat style gaskets or types other than the oem tapered type, run the risk of cracking the walls of the port, especially through the stud threads. It had something to do with expansion and contractions between the different materials. And DO NOT over tighten the flange nuts. it's only like 6-8 ft lbs. And the oem nuts are flat on the back and tend to walk off. Last time i replace the nuts, i used 5/16" fine flange nuts with the lil "burs" on the back of them...It works like a lock washer so they don't back off the threads.
self_locking_hexagon_flange_nuts_steel.jpg
After you fix the header, i suggest going through every nut and bolt securing the exhaust system including all brackets and hardware to make sure they are tight. Exhaust studs usually break or nuts come loose because of vibration due to loose hardware on the exhaust somewhere.
 
Thanks for all the help. I got the headers off and back on had to take a break to take the family to eat but will get it all back together tomorrow.


BIG[up] to all that helped me out and to Buellxb in general [up][up][up][up][up][up][up][up][up][up][up][up]
 
Damn Curtis you've been having some bike issues lately......glad you are keeping at it and not slacking like somebody I know..... :)
 
/\ LOL


Ok just got it back together and it's smoking. Is this normal? The gaskets seem to be coated with something plus I sprayed quite a bit of pb blaster on the studs yesterday which got other places too. I let her run for like five minutes and shut her down cause it was still smoking. Smoke appears to be coming from the headers. Any help greatly appreciated.

Thanks
 

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