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I Once Again Screwed The Pooch!

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  • #1

    I Once Again Screwed The Pooch!

    So, it's confirmed thst the OEM exhaust Gods hate me! I can never get those exhaust studs to show enough thread in the flanges. I can usually get one or two pipes, but the other two give me issues. New gaskets, no residue, all installed by the book, all tricks tried.

    So, the only thing I can do is attempt to remove the exhaust studs. "Ohhhhh noooo" I hear you say? Broken studs? Nope, none broken. In-fact, all seven came out with my vice grips. It's the #2 cylinder, inside stud giving me issues. It's marred-up pretty good from the vice grips. My hands hurt BAD from the pressure of the vice grips. So, I just bought a torch, and will attempt to head the cylinder and and turn the stud with the vice grips. If I cannot get it out, I'll pull the head and see if someone can weld a nut to the stud and hope it does not break.

    Worst-case, I take it to a machine shop and have it removed. It's only April, so I'm not too stressed at this point.
    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
    No-go. head is coming off and cross my fingers it does not break.
    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

    • #3
      I know you did this, I'm sure but how many gaskets are in the exhaust ports ?
      76 XS650 C ROADSTER
      80 XS650 G Special II
      https://ibb.co/album/icbGgF
      80 XS 1100 SG
      81 XS 1100LH/SH DARKHORSE
      https://tinyurl.com/k6nzvtw
      AKA; Don'e, UD, Unca Don'e

      Comment

      • #4
        Once again, I highly recommend this tool.......

        http://www.amazon.com/Irwin-Industri.../dp/B0000CCXVZ
        Greg

        Everybody is a genius. But if you judge a fish by its ability to climb a tree, it will live its whole life believing that it is stupid.”

        ― Albert Einstein

        80 SG Ol' Okie;79 engine & carbs w/pods, 45 pilots, 140 mains, Custom Mac 4 into 2 exhaust, ACCT,XS850 final drive,110/90/19 front tire,TKat fork brace, XS750 140 MPH speedometer, Vetter IV fairing, aftermarket hard bags and trunk, LG high back seat, XJ rear shocks.

        The list changes.

        Comment

        • #5
          Hey Done- One

          Greg- Thanks for the recommendation. I have the Harbor Freight version of that. The stud is too small for the smallest extractor to grab it.
          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

          • #6
            You may have boogered the end too much and ground it down with the vice grips. I've gotten broken studs out with these as long s there's enough of the stud sticking out the get ahold of.

            Great for rounded oil filter can bolts too.
            Greg

            Everybody is a genius. But if you judge a fish by its ability to climb a tree, it will live its whole life believing that it is stupid.”

            ― Albert Einstein

            80 SG Ol' Okie;79 engine & carbs w/pods, 45 pilots, 140 mains, Custom Mac 4 into 2 exhaust, ACCT,XS850 final drive,110/90/19 front tire,TKat fork brace, XS750 140 MPH speedometer, Vetter IV fairing, aftermarket hard bags and trunk, LG high back seat, XJ rear shocks.

            The list changes.

            Comment

            • #7
              If you haven't muffed the threads too much, find a couple metric nuts and double nut it. Use the wrench on the closest one to the engine and tighten down against the first one... and just keep turning.

              My local auto parts store carried the right exhaust studs that I needed.
              Try your hardest to be the kind of person your dog thinks you are.

              You can live to be 100, as long as you give up everything that would make you want to live to be 100!

              Current bikes:
              '06 Suzuki DR650
              *'82 XJ1100 with the 1179 kit. "Mad Maxim"
              '82 XJ1100 Completely stock fixer-upper
              '82 XJ1100 Bagger fixer-upper
              '82 XJ1100 Motor/frame and lots of boxes of parts
              '82 XJ1100 Parts bike
              '81 XS1100 Special
              '81 YZ250
              '80 XS850 Special
              '80 XR100
              *Crashed/Totalled, still own

              Comment

              • #8
                Tried the double nut first. Was a no-go. Stud is out. Head goes back on in the morning.
                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

                • #9
                  I go to the local auto parts store, and look for the spinning rack with the red packs on it. The Chevy small block, late engine, uses the 8mm studs, and comes with really nice shoulder nuts all for about $5. Studs are the correct length for the early standard engine, and will fit the specials as well.
                  Ray Matteis
                  KE6NHG
                  XS1100 E '78 (winter project)
                  XS1100 SF Bob Jones worked on it!

                  Comment

                  • #10
                    I keep a stick of SS allthread 8mm x 125 and cut them as I need them in any length I want.

                    Works for a lot of other stuff too.
                    Greg

                    Everybody is a genius. But if you judge a fish by its ability to climb a tree, it will live its whole life believing that it is stupid.”

                    ― Albert Einstein

                    80 SG Ol' Okie;79 engine & carbs w/pods, 45 pilots, 140 mains, Custom Mac 4 into 2 exhaust, ACCT,XS850 final drive,110/90/19 front tire,TKat fork brace, XS750 140 MPH speedometer, Vetter IV fairing, aftermarket hard bags and trunk, LG high back seat, XJ rear shocks.

                    The list changes.

                    Comment

                    • #11
                      Didn't they have two lengths of studs as they changed the depth of the exhaust header ring?

                      John
                      John is in an anonymous city with an Alamo (N29.519227,W-98.678980)

                      Go ahead, click on the bikes - you know you want to...the electrons are ready.
                      '81 XS1100H - "Enterprise"
                      Bob Jones Custom Navy bike: Tkat brace, EBC floating rotors & SS lines, ROX pivot risers, Geezer rectifier, new 3H3 engine

                      "Not all treasure is silver and gold"

                      Comment

                      • #12
                        Yes. Special vs. Standard. I saw what the issue was. Some of the exhaust studs were installed backwards, and some normal. Not sure if the long end or short end goes in the head, but i bought much longer studs (not using stock cylindrical nuts).
                        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

                        • #13
                          Head is back on, no issues. Dots align perfectly. Back to square one with the exhaust 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.

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