The exhaust is one sensitive piece

[Guest]

So I installed a new kickstand because my last one buckled in from all the rust. I was in such a rush to put the exhaust back on that I totally stripped many of the bolts. I've gotten it close, but not quite flush. This makes the fuel/air mixture way to lean, I think. I can't get the thing out of second gear and it feels like it's going to die if I try to go above 3500 rpms.

Does this sound like the exhaust system is simply not being mounted correctly, or a bigger problem? These exhaust pipes are supper sensitive to where they're placed.

[posplayr]

No...............

[ryanrod]

You're scaring me man.

[posplayr]

You're scaring me man.

If you are covering the exhaust ports at the head I just can't see you changing thaw afr that much. Did leave the can off?

[eil]

If the headers are not sealed against the head, then you have a very leaky exhaust which could make it run lean, not rich.

You will probably have to remove the exhaust, fix the stripped threads, and put it back on more carefully this time. Did you install the header gaskets? You might need new ones.

[posplayr]

I guess poor fit means different things to different people.

[ryanrod]

I'm just going to drill in where I made the boo boo and go up a size. Tack in some nice bolts that way I don't have to bother with this whole stripping business. Hopefully this fixes the problem. It's running incredibly lean and it keeps wanting to die. This thing is my freedom WHEN it runs good.

[hjfisk]

I'm just going to drill in where I made the boo boo and go up a size. Tack in some nice bolts that way I don't have to bother with this whole stripping business. Hopefully this fixes the problem. It's running incredibly lean and it keeps wanting to die. This thing is my freedom WHEN it runs good.

Don't go at this half heartedly. Do it correctly or you will wish you had. Use the search function on this site and you will read more exhaust horror stories than you care to. Just a word of caution.

[BigD_83]

I'm just going to drill in where I made the boo boo and go up a size. Tack in some nice bolts that way I don't have to bother with this whole stripping business. Hopefully this fixes the problem. It's running incredibly lean and it keeps wanting to die. This thing is my freedom WHEN it runs good.

What is your machining background? If you don't have access to the proper jigging and good tools, this is a job that is better done by professionals.

Given your location, there might even be a few members around you that are tooled up, and could be incentivized to help out. If you can't find someone on here, you could find a great machinist in your area. Up here, you'd be looking at around $40.00/bolt if you take the engine out of the frame. I suspect it'd cost you less there.

[81GS850]

Seriously? What is the reasoning for "going up a size" when you could install helicoils and use the same size bolt. Also are you talking tacking as in tac welding? How are you gonna do that on aluminum and steel? Waaaay more more than needed. Helicoil the bad holes and thread chase the rest. Then, be more careful on tightening things down. Also you can go to Oreillys if there is one around and they have a "stud" set for some Ford vehicle hanging up in the miscellaneous parts rack that has the right thread pitch and comes with the nuts. I haven't tried it yet but I will be studding the exhaust so I don't pull the threads out again.

[Rob S.]

Year, model?

(Brand?!?)

[60ratrod]

+1 on helicoils. they are fairly easy to do and i've done several on my project cars over the years, mostly on intake manifolds. and the helicoils will actually be a stronger thread that just aluminum alone. you can get the helicoil kit at napa. they aren't that much

[rapidray]

PLEASE call me at 714--356-7845 so I can help you NOT do things you shouldn't do! Also, please help us help YOU by putting the year, engine size, & model of your bike in your post. Thanks,
Ray

[eil]

+1 on helicoils and studs. Planning to fit studs on my 850 when I get around to finally doing the top-end rebuild.

[ryanrod]

Thanks for all the suggestions on the helicoils, drilling in some new bolts could've gone terribly wrong, especially with my lack of experience . It's a problem with the ignition system, because the solenoid will clack all day, and I even get a puff out of the exhaust upon first try. After that nothing, the engine won't turn over.

It's gotta be a weak ignition system.