stock exhaust bolts too short for V&H's

[jhelbig]

I got new Vance & Hines 4-1 exhaust to put on my '79GS1000EN and the directions say to use the STOCK exhaust bolts. So I got those from Bike Bandit and they are WAY TOO SHORT. The bolts need to go through a flange and they don't nearly reach. I took out the old gaskets and put in new ones.
I called everyone that I got the stuff from and they all confirmed I got the right parts. Bike Bandit and Dennis Kirk could only recommend that I call Vance & Hines, but I can't even get them on the phone. So I searched on here and saw that one guy had the same problem, but he's not accepting PM's (Keith Krause). So Keith or anyone else, what size bolts did you need to use and where did you get them? Thanks!! I'm really desparate to get these pipes on and finish this project!! I really want to ride it!

By the way, the directions said I was supposed to get other bolts in the package, but not to use them (only for certain year kat's). Well, I didn't even get those. I think V&H's is slipping some in the QA dept.

[rphillips]

Don't know why you don't have what you need, but I'd get studs to replace the bolts. In the future nuts will come off the studs much easier than bolts will come out of the head.

[bwringer]

Go to Ace Hardware, get some longer bolts (I like stainless allen heads myself), and use looooooots of antiseize.

With almost all aftermarket goods, the application data for older bikes is highly suspect. Just be happy that the exhaust fits.

[Agemax]

just measure up and get some longer bolts, not a difficult fix really! as mentioned, get some nice stainless allen bolts and smother them with anti sieze.

[Kaiser Sosei]

For my '80 GS1100E I used 8mm X 1.25mm X 30mm. I don't know if that's stock or not, just going by what I ordered from boltdepot.com. I got socket head stainless. They were $.71 a piece and the part number is #6436.

[argonsagas]

just measure up and get some longer bolts, not a difficult fix really! as mentioned, get some nice stainless allen bolts and smother them with anti sieze.

That is what you need to do, although I would also suggest you use studs instead of bolts because they are easier to work with and reduce chances of stripping threads in the head.





To measure the depth inside the head use a bolt of identical thread and diameter, insert it all the way and then put a mark on the bolt flush with the head

After that, add on the thickness of the parts plus any washers you will be adding and you have the total length. (unless you use studs, as they will be a bit longer to afford extra threads for the nuts to be installed.)

If using bolts I would recommend using two mm less than the total from above to allow for stretching or alternate washers.

USE LOTS of ANTI-SIEZE.

Torque the bolts into place....you do not want to strip the head.

[Octain]

To measure the depth inside the head use a bolt of identical thread and diameter, insert it all the way and then put a mark on the bolt flush with the head

I used a popcycle stick.

[OldVet66]

The ones in my V&H are 1 3/8" long.

[bwringer]

The ones in my V&H are 1 3/8" long.

Inches, barleycorns, and other outdated systems of measurements are filthy leftovers of the colonial age...

You meant 35mm, right?

[rphillips]

"NO" !!!!!, he meant 1 3/8". Where are you from??? Japan????

[argonsagas]

Inches, barleycorns, and other outdated systems of measurements are filthy leftovers of the colonial age...

You meant 35mm, right?

Sorry Brian, but this is a man who likes beer.

He understands that it takes 8 sips to make a short drink and 36 short drinks make a yard of ale, so with the aid of a popsicle stick he needs only 3 sips and one short drink to find the exact drop in fluid level as a bona fide measure. Of course, if he bolts too much down at a time it creates the effect of a draught, so his tongue gets loose even as he gets tight and later the stick becomes his depressor.

[jhelbig]

Thanks for all the great advice! Couple of questions. First, I don't have the stock bolts anymore. I sent them back to bikebandit. Never had the originals, I guess the PO lost them. So how do I know what the threads are( I think its called the pitch?)?
Second, studs sound like the way to go, so do I have to take it to a shop to get them put in?
And I don't think a 1 3/8" bolt would even reach past the end of the pipes from the flange! It's not right I think. From the flange to the pipes is REALLY FAR. The flanges stick out, not even close to the motor. I'm at work now, but if I get a chance I'll post pics tonight. Again, thanks for all the replies!

[jhelbig]

Sorry Brian, but this is a man who likes beer.

He understands that it takes 8 sips to make a short drink and 36 short drinks make a yard of ale, so with the aid of a popsicle stick he needs only 3 sips and one short drink to find the exact drop in fluid level as a bona fide measure. Of course, if he bolts too much down at a time it creates the effect of a draught, so his tongue gets loose even as he gets tight and later the stick becomes his depressor.

Thanks for the laugh! That piece of work made my day!