Adventures in exhaust replacement

[rphillips]

Wouldn't use loctite on studs nor bolts, Yoy don't want it to be there forever. Like now, you want to get them out. Anti-seize would be a good idea. Those things don't vibrate & fall out, but if one did, no problem to put one back in. Much easier than what you are into now. There's a good chance that if they were installed with anti-seize, they wouldn't have twisted off in the first place. Just my opinion.

[doctorgonzo]

Wouldn't use loctite on studs nor bolts, Yoy don't want it to be there forever. Like now, you want to get them out. Anti-seize would be a good idea. Those things don't vibrate & fall out, but if one did, no problem to put one back in. Much easier than what you are into now. There's a good chance that if they were installed with anti-seize, they wouldn't have twisted off in the first place. Just my opinion.

I haven't converted to studs, mine are bolts, 2 of which were sheared off by the PO. The new bolts I put in got a healthy dose of anti-seize. We got sidetracked into a discussion of replacing bolts with studs, which I will probably do when I swap the head eventually.

[TheCafeKid]

New V&H should arrive today, so last night took my bike to a friend's garage to remove the old system and take care of the two bolts I knew were missing and likely sheared off. The horror show I found still has me a little nauseous. The first bad sign, "wow, none of these bolts are very tight". The reason for that... 4 of the 8 holes had ALREADY been heli-coiled. 2 of the remianing 4 barely had any threads, 1 was oversized and had no threads at all (1 of the 2 missing ones), and 1 had a sheared off bolt with the hole around it chewed all to hell like someone had tried to get at the tip of the bolt by removing the metal around it to get a grip on it. I tapped the two with minimal threads and they look like they have enought to hold, I heli-coiled the 1 oversized one (which started to dribble oil after I ran the tap down it, didn't drill AT ALL just ran a tap down it). The sheared off one we welded a nut to it 3 times, but it wouldn't hold. Managed to get a drill in it for an extractor, which promptly broke off the first try at turning it out. My mechanic friend says "you might as well give up on that one, you'll never drill out that tap, the steel is too tough".

SO... I guess tonight I am going to mount the exhaust with 5 of the 8 bolts heli-coiled, and leave the 1 bolt (the sheared one) off. I hope I can get it to seal.

Hopefully it will make it through the rest of this season as I start looking for a head...

Oi, what are you doing with your old exhaust? Im looking for a right side pipe, just the 4 cyl pipe and meg. Mine looke REALLY good except for the meg where it got dropped and scuffed to hell years and POs ago.

[doctorgonzo]

Oi, what are you doing with your old exhaust? Im looking for a right side pipe, just the 4 cyl pipe and meg. Mine looke REALLY good except for the meg where it got dropped and scuffed to hell years and POs ago.

It's for sale now that you mention it. Talking to one member about it, but nothing solid. On a side note. I know you are looking for an 8 valve 1100 head. I need one (or a 1000 head) if you run across more than the one you need, let me know. there are TWO 16 valve 1100 hundred heads on ebay right now, but not one 80 or greater 1000 head or 8 valve 1100 head.

[Jethro]

Wouldn't use loctite on studs nor bolts, Yoy don't want it to be there forever. Like now, you want to get them out. Anti-seize would be a good idea. Those things don't vibrate & fall out, but if one did, no problem to put one back in. Much easier than what you are into now. There's a good chance that if they were installed with anti-seize, they wouldn't have twisted off in the first place. Just my opinion.

Agreed. Anti-sieze with the copper colored stuff. And I hear of some folks not using exhaust gaskets, it's important to know that the torque depends on those gaskets- it's foolish to go without- new ones each time is best.

[TheCafeKid]

It's for sale now that you mention it. Talking to one member about it, but nothing solid. On a side note. I know you are looking for an 8 valve 1100 head. I need one (or a 1000 head) if you run across more than the one you need, let me know. there are TWO 16 valve 1100 hundred heads on ebay right now, but not one 80 or greater 1000 head or 8 valve 1100 head.

*I* am not looking for an 1100 head. And im not positive, but I think *maybe* JDPowel had one for sale. If not, I WILL keep an eye out for you. Lemme know if nothing happens with those pipes. Hows the right side pipe look?

[chef1366]

Nathan
Take that head to a machine shop and get it fixed.

[doctorgonzo]

Nathan
Take that head to a machine shop and get it fixed.

What can they do.... I know they could extract the bolts, but what about the now 5 or 6 oversized holes.... can they do better than an insert?

[chef1366]

They can fill and retap.
Either way you need to pull the head. If there is nothing wrong with your head besides the exhaust threads just get it fixed.

[doctorgonzo]

They can fill and retap.
Either way you need to pull the head. If there is nothing wrong with your head besides the exhaust threads just get it fixed.

I know you're right... it was worth the couple hundred for a head to be able to get it re-built and ready to bolt on while still having the bike to ride with the old head, but no luck finding one in a hurry... so I may have to take that route, pulling it and taking to shop.

[doctorgonzo]

I know you're right... it was worth the couple hundred for a head to be able to get it re-built and ready to bolt on while still having the bike to ride with the old head, but no luck finding one in a hurry... so I may have to take that route, pulling it and taking to shop.

Nope.. Called 3 machine shops and as soon as I said one had an extractor broken off in it they said "well nothing we can do, never get it drilled out".

[Dogma]

Nope.. Called 3 machine shops and as soon as I said one had an extractor broken off in it they said "well nothing we can do, never get it drilled out".

Nobody has a ram EDM anymore? You might have to look around for a non-automotive machine shop. Some shops even specialize in the various types of EDM. Even the smaller job shops used to have simple ones for burning out broken taps. They are sometimes called hole-poppers.

[doctorgonzo]

Nobody has a ram EDM anymore? You might have to look around for a non-automotive machine shop. Some shops even specialize in the various types of EDM. Even the smaller job shops used to have simple ones for burning out broken taps. They are sometimes called hole-poppers.

I'll try that. Thanks Dogma. I MAY have found a spare head as well.

[timelapseracing]

exhaust bolt and oil

I did a search looking for info on exhaust head bolts and oil and this thread came up - hope you don't mind it being pulled back out. I was chasing an oil leak that I thought was a head or valve cover gasket. It turned out the first exhaust head bolt on the ignition side of the motor was pushing oil past the bolt. In reading your thread, it rang similarly, I think the bolt had previously been tapped - the bolt is a little looser than the others - and had backed out some.

Is it normal for there to be oil pressure on the back of that bolt or do I have a head problem? The bike runs pretty well - even with the oil spray. I pulled the bolt, put some high temp RTV (orange) and some mild strength loctite on the bolt - seems to be ok on the oil leak.

I'm leaning toward the studs option too or drilling and wiring all the exhaust bolts - and fyi - www.mcmaster.com/ is an excellent source for hardware of all kinds - use them all the time on my racecar.

Just learning my way around the GS motor - oh yeah - '79 GS850G.

Thanks,
Jason.

[Dave8338]

I did a search looking for info on exhaust head bolts and oil and this thread came up - hope you don't mind it being pulled back out. I was chasing an oil leak that I thought was a head or valve cover gasket. It turned out the first exhaust head bolt on the ignition side of the motor was pushing oil past the bolt. In reading your thread, it rang similarly, I think the bolt had previously been tapped - the bolt is a little looser than the others - and had backed out some.

Is it normal for there to be oil pressure on the back of that bolt or do I have a head problem? The bike runs pretty well - even with the oil spray. I pulled the bolt, put some high temp RTV (orange) and some mild strength loctite on the bolt - seems to be ok on the oil leak.

I'm leaning toward the studs option too or drilling and wiring all the exhaust bolts - and fyi - www.mcmaster.com/ is an excellent source for hardware of all kinds - use them all the time on my racecar.

Just learning my way around the GS motor - oh yeah - '79 GS850G.

Thanks,
Jason.

Unless I'm WAY off base...the exhaust bolts DO NOT tap into an oil gallery...on anything, if so, I've never seen it? Sounds like you have some blow-by that is showing itself as "said issue". Is it possible that your valve cover gasket is leaking and just looks as you describe?

EDIT: Well there's your answer. Thanks, DOC!