exhaust blots too long

[digitalsam]

I had to replace the cylinder head assembly when I tore apart the engine on my 80xs special. The new exhaust bolts are longer than the old. It seem to remember that it was a year to year length change. Anyhooo. The bolts I have are from the old head and as they are hex bolts, they are too short.

Any suggestions on a work around, or do I need "Exhaust" bolts? Can I use any old bolt?

begin praying, I am going to start this thing up as soon as I get the exhaust installed. My wife is afraid that the thing is going to explode when I start it. The promise of life insurance money doesn't seem to be much of a comfort.

[DGXSER]

MY 81 has studs inserted into the block and hex head cap nuts that go on the stud after the exhaust is installed.

[gareth]

I put standard pipes on my special. The bolts were too short. I pulled them out of the head and reversed them. On my 79 SF the part of the exhaust stud that actually threaded into the cylinder head was longer. I did plan on using regular bolts, cutting off the heads and making studs that way, but tracking down metric bolts was a problem on the day and I was keen to get the bike on the road. The reversed studs didn't bottom out on the cylinder head, but they held fine.

[Edit..Er, Um.... Well.... it might not work the other way...}

Your Bike May Vary.

[Crazcnuk]

It's not a year thing. The standards have longer studs than the specials.

I assume the standard exhaust must have thicker flanges, but all mine like the short studs so they must be off of specials.

I just change them as needed.

[Cobia]

Possible solution

I just used several SS washers to make up for the extra length. My flanges were of the ribbed fancy kind and the washers disappeared into the recesses (holes), so you can't even see them.

[digitalsam]

SS washers

Is an SS washer different from a regular ol washer? I have the fancy flanges too.

[HobbyMan]

I think it may be year related. I took an exhaust off of a 79 standard and put it on an 80 standard. The lengths were different. I just swapped the studs as well

[GARTHXS]

washers

I have a bassani exhaust on my 78 and I just used a couple of washers an alock washer and that has held for a year or so!!

[latexeses]

digitalsam,

I'm pretty sure cobia was talking about stainless steel washers when he made the "SS washers" comment. You can find them where you get your other metric hardware. Ace Hardware seems to be a common source.
Good luck.

[digitalsam]

Used three lock washers on each pipe and it did the trick. Could not find regular washers that had a small OD and a large ID. Should have probably used four washers, but three worked well and are all well hidden.

Thanks for the advice.

[65oldsboy]

Longer studs for a Kerker??

Just got around to doing some work on the XS. (SWMBO is at the beach with the kids. I couldn't get off of work. Oh, Darn.) Had to take off the Kerker exhaust to get the oil filter off. Found out that the PO didn't use any exhaust gaskets when he put the Kerker on. Hopefully that didn't cause any major issues. Any way, when trying to put the exhaust back on (with new exhaust gaskets), the additional thickness from the gasket makes the studs too short. Sheeot, I was hoping to get the beast fired up tonight. Guess it will have to wait until I get some longer studs. Anybody with a Kerker have the same problem?

The parts bike that I just picked up has the short studs also. SWMBO is gonna kill me for giving her another "surprise." I waited until she was at the beach to pick up the partser.

[Bigfoot]

I had the same problem, bolts were too long for the exhaust. I used some thick wall copper pipe of the right diameter. Cut some spacers, problem solved. Think it cost me a buck or so.

[65oldsboy]

My studs are too short, not too long. Gonna have to get to the hardware store to get some longer ones. Might as well give the Kerker a good polishing while I have it off.

So far, have found 2 PO mess-ups: 1) no exhaust gaskets installed 2) the oil filter washer was missing (at least the spring was still there). The parts bike is starting to pay off already. Saved me at least 25 cents for a replacement washer.

[65oldsboy]

I got the longer exhaust studs at a local auto parts store. Anybody got a cheap source for the allen head nuts? My nuts are pretty rusty. (Insert gonad joke here.)