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Removed my exhaust and found some issues

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Old Jan 18, 2009 | 06:11 PM
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AmmoDan's Avatar
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Default Removed my exhaust and found some issues

I'm getting ready to put on a new exhaust, so I removed my existing pipes this afternoon. First issue that came up was the left bolt on my forward cylinder is broken in half & the nut was nowhere to be found. Can I replace this bolt or could I just connect the exhaust with one bolt?

The second issue, which concerns me more, is the part of the transmission case that I have to bolt my mounting bracket onto has the bottom hole completely stripped out. (see picture) How can I fix this problem? My thoughts were to maybe use a larger bolt to grab onto the edges of the hole. Other than that, I figure I would have to replace the casing itself, which I really don't want to get into. Can I get by with one fastener holding the exhaust in that area (I guess I have been getting by with it...)

Any thoughts?
 
Attached Thumbnails Removed my exhaust and found some issues-0118091341.jpg  
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Old Jan 18, 2009 | 06:18 PM
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Hmm...you can re-tap the hole. If it's too far gone, try a helicoil. I believe they have an insert that will go in and then you re-tap it for the size you need.
 
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Old Jan 18, 2009 | 07:12 PM
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Is this on the 2008 Fat bob? Take it back in and get warranty work done to fix it.
 
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Old Jan 18, 2009 | 07:17 PM
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+1 ...

Originally Posted by bluetoys
is this on the 2008 fat bob? Take it back in and get warranty work done to fix it.
 
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Old Jan 18, 2009 | 07:27 PM
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I would put it all back together and take it into the dealer. I just would not tell them I had it apart.
 
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Old Jan 18, 2009 | 08:12 PM
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I didn't even think of the warranty...sometimes the most obvious isn't very obvious to me. Good idea.
 
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Old Jan 18, 2009 | 08:15 PM
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So how am I supposed to explain the defects if I wasn't supposed to take the exhaust off?
 
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Old Jan 18, 2009 | 08:19 PM
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look inside the hole of transmission that you think is stripped with a flashlight, it gets smaller inside. 2 of the bolts are thinner then the rest. i thought mine was stripped as well just to find that it requires a thinner bolt.
 
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Old Jan 18, 2009 | 09:49 PM
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As for the bolt on the head, you need two. You need to take the broken one out, and replace it. One bolt will not seal the header pipe to the head, and you can have a major exhaust leak, that will sound like crap and cause undue heat in the area.
 
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Old Jan 19, 2009 | 04:17 AM
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Originally Posted by archergodwin
As for the bolt on the head, you need two. You need to take the broken one out, and replace it. One bolt will not seal the header pipe to the head, and you can have a major exhaust leak, that will sound like crap and cause undue heat in the area.
#1 on replace the bolt. An exhaust leak there could actually etch the surfaces, complicating matters and make getting a seal nearly impossible and will raise the temp of the exhaust valve, potentionally burning it. As far as the transmission is concerned, you need all the bolts to maintain the strength and integrity of the side cover. If it is indeed stripped, a Heli-coil would be the superior (and easiest) way to fix it, actually making the repair stronger than origional. When I built racing engines, EVERY threaded aluminum bolt hole got Heli-coiled automatically.

Unless the Stealer is pretty open minded, you may have a difficult time convincing him you had nothing to do with it... IMHO. Great time to learn some good machining / maintenance skills. There are a zillion articles out there explaining how to do this. Take you time and be careful and it will be a piece of cake (except maybe getting the old stud out of the head, but it can be done with good results if care is taken).
 
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