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Installing New Exhaust Studs

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  • #1

    Installing New Exhaust Studs

    With my '79 build finally underway (thanks to IanDMacDonald for some much needed parts) I figured I'd seek out some suggestions to not repeat some of my past mistakes. The '79 has a few missing (not broken off) exhaust studs that I just ordered from my Yammy dealer that should be in by the end of the week. Problem is, last time I tried installing a new exhaust stud (on the '78) it broke off in the head and I had to do the ol' "tig weld a nut onto the snapped off stud" trick to get it out.

    I usually have a pretty good hand at estimating torque but apparently not that time. To drive the stud in I actually had to use a small cheater bar because even though it wasn't even close to being in all the way it was taking well over 14.5 ft-lbs to drive it in. Is there some special trick to making these studs go in easier? Because last time it was going pretty well until I bottomed out the stud and broke it off . Any tips would be appreciated.
    78 E - 2to1 exhaust, dynatek coils, special headlight [SOLD!]
    79 F - gas tank refurb, headgasket change, straight pipes, late model carbs, virago lowering shocks, special headlight and gauges, TC fuse block, GSXR-1100 carbs (WIP)


    "May my tires not fail me, nor my engine grow cold"
    Tags: None
  • #2
    Having recently had a broken stud I too am interested in any others experience.
    Phil
    1981 XS1100 H Venturer ( Addie)
    1983 XJ 650 Maxim
    2004 Kawasaki Concours. ( Black Bear)

    Comment

    • #3
      I believe those are M8 studs. You could get a tap and coat it with grease (catch any shavings), and then chase the threads in the head. Also, coat the studs in some type of lubricant prior to install.
      1979 XS1100F
      2H9 Mod, Truck-Lite LED Headlight, TECHNA-FIT S/S Brake Lines, Rear Air Shocks, TKAT Fork Brace, Dyna DC-I Coils, TC Fuse Block, Barnett HD Clutch Springs, Superbike Handlebars, V-Star 650 ACCT, NGK Irridium Plugs, OEM Exhaust. CNC-Cut 2nd Gear Dogs; Ported/Milled Head; Modded Airbox: 8x8 Wix Panel Filter; #137.5 Main Jet, Viper Yellow Paint, Michelin Pilot Activ F/R, Interstate AGM Battery, 14MM MC, Maier Fairing, Cree LED Fog Lights.

      Comment

      • #4
        Yup, I too would run a bottoming tap into the hole first and clean it all up as much as possible before hand and then try.

        Measure the depth of the hole as well and then mark it on the stud so you can see where you need to stop.
        Nathan
        KD9ARL

        μολὼν λαβέ

        1978 XS1100E
        K&N Filter
        #45 pilot Jet, #137.5 Main Jet
        OEM Exhaust
        ATK Fork Brace
        LED Dash lights
        Ammeter, Oil Pressure, Oil Temp, and Volt Meters
        Green Monster Coils
        SS Brake Lines
        Vision 550 Auto Tensioner

        In any moment of decision the best thing you can do is the right thing, the next best thing is the wrong thing, and the worst thing you can do is nothing.

        Theodore Roosevelt

        Comment

        • #5
          A thread chaser would actually be preferable to a tap.
          Nathan
          KD9ARL

          μολὼν λαβέ

          1978 XS1100E
          K&N Filter
          #45 pilot Jet, #137.5 Main Jet
          OEM Exhaust
          ATK Fork Brace
          LED Dash lights
          Ammeter, Oil Pressure, Oil Temp, and Volt Meters
          Green Monster Coils
          SS Brake Lines
          Vision 550 Auto Tensioner

          In any moment of decision the best thing you can do is the right thing, the next best thing is the wrong thing, and the worst thing you can do is nothing.

          Theodore Roosevelt

          Comment

          • #6
            Ahh, I did not know there was a difference. I just googled that. Good to know for the future.
            1979 XS1100F
            2H9 Mod, Truck-Lite LED Headlight, TECHNA-FIT S/S Brake Lines, Rear Air Shocks, TKAT Fork Brace, Dyna DC-I Coils, TC Fuse Block, Barnett HD Clutch Springs, Superbike Handlebars, V-Star 650 ACCT, NGK Irridium Plugs, OEM Exhaust. CNC-Cut 2nd Gear Dogs; Ported/Milled Head; Modded Airbox: 8x8 Wix Panel Filter; #137.5 Main Jet, Viper Yellow Paint, Michelin Pilot Activ F/R, Interstate AGM Battery, 14MM MC, Maier Fairing, Cree LED Fog Lights.

            Comment

            • #7
              Taps cut threads, thread chaser pushes damaged threads back into place if possible.
              Nathan
              KD9ARL

              μολὼν λαβέ

              1978 XS1100E
              K&N Filter
              #45 pilot Jet, #137.5 Main Jet
              OEM Exhaust
              ATK Fork Brace
              LED Dash lights
              Ammeter, Oil Pressure, Oil Temp, and Volt Meters
              Green Monster Coils
              SS Brake Lines
              Vision 550 Auto Tensioner

              In any moment of decision the best thing you can do is the right thing, the next best thing is the wrong thing, and the worst thing you can do is nothing.

              Theodore Roosevelt

              Comment

              • #8
                Couldn't find a thread chaser at the local hardware store so I picked up a 8mm (1.25) tap and wrench and it worked like a charm. Is there any reason I should need to put a high temp thread locker in? Or will the initial heating/cooling lock it in place during start up?
                78 E - 2to1 exhaust, dynatek coils, special headlight [SOLD!]
                79 F - gas tank refurb, headgasket change, straight pipes, late model carbs, virago lowering shocks, special headlight and gauges, TC fuse block, GSXR-1100 carbs (WIP)


                "May my tires not fail me, nor my engine grow cold"

                Comment

                • #9
                  Instead of tread lock I would apply a never seize type product. There are some very good ones at marine supply stores although not cheap, but you can use them for just about everything you're putting together and may want to replace eventually.
                  1980G Standard, Restored
                  Kerker 4 - 1
                  850 Rear End Mod
                  2-21 Flashing LED Arrays on either side of license plate for Brake Light Assist, 1100 Lumen Cree Aux Lights,
                  Progressive springs, Showa rear shocks
                  Automatic CCT
                  1980GH Special, Restored
                  Stock Exhaust, New Handlebars, 1" Spacer in Fork Springs, Automatic CCT, Showa Rear Shocks
                  '82 XJ1100 (Sold)
                  Automatic CCT, RC Engineering 4 X 1 Exhaust, K&N Pods, #50 Pilot Jets, YICS Eliminator. Sorely missed.

                  Comment

                  • #10
                    I think taps are tapered so it may not cut sufficiently at the tip.
                    go for the anti seize.
                    throw your easy outs in the trash.
                    a steel bolt and some wd40 vs your aluminum block will work too, but if the tap worked, great.
                    Last edited by Gallaecus; 09-29-2013, 04:21 PM.
                    Steven


                    1981 XS 1100 LH
                    1979 XS 1100 SF

                    Comment

                    • #11
                      Originally posted by Gallaecus View Post
                      I think taps are tapered so it may not cut sufficiently at the tip.
                      go for the anti seize.
                      throw your easy outs in the trash.
                      a steel bolt and some wd40 vs your aluminum block will work too, but if the tap worked, great.
                      That's why you need a bottoming tap. It cuts nearly to the end and has a flat blunt tip rather than the tapered pointy tip of other taps.
                      Nathan
                      KD9ARL

                      μολὼν λαβέ

                      1978 XS1100E
                      K&N Filter
                      #45 pilot Jet, #137.5 Main Jet
                      OEM Exhaust
                      ATK Fork Brace
                      LED Dash lights
                      Ammeter, Oil Pressure, Oil Temp, and Volt Meters
                      Green Monster Coils
                      SS Brake Lines
                      Vision 550 Auto Tensioner

                      In any moment of decision the best thing you can do is the right thing, the next best thing is the wrong thing, and the worst thing you can do is nothing.

                      Theodore Roosevelt

                      Comment

                      • #12
                        Under emergency circumstances, a plug or taper tap can have the tip ground back to make an ersatz bottoming tap. Your local Ace Hardware will probably not have all three styles of taps in the metric size you need.
                        Necessity is a mother!

                        CZ

                        Comment

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