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Don't Stone Me . . .

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  • #1

    Don't Stone Me . . .

    So, got the engine all painted and fitted with Euro parts, thanks to James England. Any of you ever carry this engine up the stairs on a dolly by yourself??? Oh my goodness I'll have streaks in my pants for weeks to come! Installed the engine (by myself, a real pain with the middle drive hanging up). Installed TC's fuse box, installed the carbs, etc.

    Got to the exhaust. I had to mentally prepare myself for it, as I always have issues with it. This time it went smoother. Took a break and read the manual for install instructions. Saw that you're supposed to loosen the #2/3 pipes. Go back outside, curse the exhaust system a few times, and then realized I forgot to loosen the #2/3 pipes, lol. #3 goes right in with no issues. #2? Of course there are issues. Studs are just too damn short. Not enough thread for the nut to bite. What do I do to solve my issue? Went downstairs and alternated between sanding dremel attachment, and a half-inch metal drillbit. I countersunk the header flange just enough for the nut to get a bite of thread. I did not remove enough material for any structual issues. It worked great, and was a great stress relief. The bike is turn-key ready. Gotta wait on that clutch arm actuator and the snow to melt, and I can go for a ride.
    Last edited by IanDMacDonald; 03-09-2014, 11:03 PM.
    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.
    Tags: None
  • #2
    What was different between 2 and 3 that 3 would not work? Studs are the same length on both, flange should be the same on both. You took this exhaust off the same bike right?

    Not that I think you did any real damage by counter sinking the nut, but I hope there is more threaded into that nut than just enough to get a bite.
    Life is what happens while your planning everything else!

    When your work speaks for itself, don't interrupt.

    81 XS1100 Special - Humpty Dumpty
    80 XS1100 Special - Project Resurrection


    Previously owned
    93 GSX600F
    80 XS1100 Special - Ruby
    81 XS1100 Special
    81 CB750 C
    80 CB750 C
    78 XS750

    Comment

    • #3
      Jat

      Hi Ian, Are you sure you only have one exhaust gasket in #3 ?
      1980 XS1100G "Dolly G" Full Dresser (with a coat of many colors )
      1979 XS1100SF (stock-euro mods planned)
      1984 XV700L Virago (to be hot-modded)
      1983 XJ750MK Midnight Maxim (semi-restored DD)
      1977 XS650D ( patiently awaiting resto)

      Sometimes it takes a whole tank of gas before you can think straight.

      Comment

      • #4
        Hi Fellas- Addressing Don first, I countersunk the flange on the front side where the nut contacts the flange, not the nut. Yes, OEM exhaust. Difference between the two? The #3 had just enough stud showing to get the nuts to bite, the #2 did not, lol. And no, the nut is all the way screwed-in, not just held-on by a bite. And Schming- No double gaskets, all new and very pretty. The only thing I can think of is two things: Scott used different studs on the bike when he had the Mac system on the bike (these seem really short), or during my stud-extraction removal adventure, I drove them into the engine further (not sure how, as that stud was frozen). So, no harm, no foul. I just don't think it's fair I had to do that. I obviously tried to double-nut the stud and pull it out first, and it was very-much stuck. So . .
        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

        • #5
          Originally posted by IanDMacDonald View Post
          Hi Fellas- Addressing Don first, I countersunk the flange on the front side where the nut contacts the flange, not the nut. Yes, OEM exhaust. Difference between the two? The #3 had just enough stud showing to get the nuts to bite, the #2 did not, lol. And no, the nut is all the way screwed-in, not just held-on by a bite. And Schming- No double gaskets, all new and very pretty. The only thing I can think of is two things: Scott used different studs on the bike when he had the Mac system on the bike (these seem really short), or during my stud-extraction removal adventure, I drove them into the engine further (not sure how, as that stud was frozen). So, no harm, no foul. I just don't think it's fair I had to do that. I obviously tried to double-nut the stud and pull it out first, and it was very-much stuck. So . .
          Might have been a good time to replace the exhaust studs!
          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

          • #6
            So you have one stud on number three that is shorter than all your other studs?
            Life is what happens while your planning everything else!

            When your work speaks for itself, don't interrupt.

            81 XS1100 Special - Humpty Dumpty
            80 XS1100 Special - Project Resurrection


            Previously owned
            93 GSX600F
            80 XS1100 Special - Ruby
            81 XS1100 Special
            81 CB750 C
            80 CB750 C
            78 XS750

            Comment

            • #7
              Originally posted by D0wn5h1ft View Post
              Might have been a good time to replace the exhaust studs!
              I started that adventure. But when I ran into the stud that refused to budge, that's when my gut told me to not tinker with things that ain't broke.

              Don- When I look at the studs down the cylinder head, it sure looks like some are longer/shorter than others. May be an illusion though. What I can tell you is that there was a thread/post regarding stud length for Standard/Special. When I pulled my studs and measured for replacement, they were not the same length as posted data.
              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

              • #8
                Originally posted by IanDMacDonald View Post
                I started that adventure. But when I ran into the stud that refused to budge, that's when my gut told me to not tinker with things that ain't broke.

                Don- When I look at the studs down the cylinder head, it sure looks like some are longer/shorter than others. May be an illusion though. What I can tell you is that there was a thread/post regarding stud length for Standard/Special. When I pulled my studs and measured for replacement, they were not the same length as posted data.
                A broken stud is no fun...I had to weld a nut on the end of mine to get it out. Good thing the heat loosened it 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
                  Originally posted by D0wn5h1ft View Post
                  A broken stud is no fun...I had to weld a nut on the end of mine to get it out. Good thing the heat loosened it up!
                  Ditto...in my XJR1300........ Not to be undertaken lightly.... Here's the warning pic...again the only stud out of eight that would not budge and needed a blob welding onto it after it sheared....

                  XS1100F 1980 European model. Standard. Dyna coils. Iridium plugs. XS750 final drive (sometimes). Micron fork brace. Progressive front springs. Geezer regulator/rectifier. Stainless 4 into 2 exhaust. Auto CCT (Venturer 1300) SOLD. New project now on the go. 1980 European model.

                  Comment

                  • #10
                    Originally posted by IanDMacDonald View Post
                    So, got the engine all painted and fitted with Euro parts, thanks to James England.
                    Nice to hear they all fitted, Ian! You'll notice the difference when riding
                    XS1100F 1980 European model. Standard. Dyna coils. Iridium plugs. XS750 final drive (sometimes). Micron fork brace. Progressive front springs. Geezer regulator/rectifier. Stainless 4 into 2 exhaust. Auto CCT (Venturer 1300) SOLD. New project now on the go. 1980 European model.

                    Comment

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