Why Do My Exhaust Studs Keep Breaking!!!!!
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Seasoned HDF Member
Joined: Apr 2017
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From: Globe AZ
Why Do My Exhaust Studs Keep Breaking!!!!!
ok, Im beginning to get a bit pissed off about this. Broke ANOTHER exhaust stud this morning. Of course its the front head, and the lower stud covered by the framerail as well. (Worst case scenario). Now for a little back story. Just did a 98" upgrade on the motor about 1500 miles ago, and replaced all four studs while the heads were off with brand new pieces. Only saving grace is that the studs screwed in easily, so should come out easy as well, once I can get an easy out in it. Exhaust is stock, and held in place with all the appropriate bolts. I use a locking nut over the flange to keep things tight. Prior to the upgrade, I had broken several of the studs and replaced them. I replaced with new during the upgrade to PREVENT this happening again, yet here I am.....
WHAT WOULD CAUSE THESE STUDS TO KEEP BREAKING with alarming regularity? Ive used all types, Harley, Aftermarket, Parts store, they all break off either flush, or just below flush with the head (on the coarse thread side of the stud) I dont over torque (snug plus a very little bit to keep from leaking with a small 1/4 drive ratchet, so cant really muscle enough to break a 5/16 grade 8 stud), WHAT AM I DOING WRONG HERE??
WHAT WOULD CAUSE THESE STUDS TO KEEP BREAKING with alarming regularity? Ive used all types, Harley, Aftermarket, Parts store, they all break off either flush, or just below flush with the head (on the coarse thread side of the stud) I dont over torque (snug plus a very little bit to keep from leaking with a small 1/4 drive ratchet, so cant really muscle enough to break a 5/16 grade 8 stud), WHAT AM I DOING WRONG HERE??
Last edited by ScottinAZ; Aug 1, 2020 at 11:10 AM.
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Joined: Apr 2013
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From: Newcastle, OK
ok, Im beginning to get a bit pissed off about this. Broke ANOTHER exhaust stud this morning. Of course its the front head, and the lower stud covered by the framerail as well. (Worst case scenario). Now for a little back story. Just did a 98" upgrade on the motor about 1500 miles ago, and replaced all four studs while the heads were off with brand new pieces. Only saving grace is that the studs screwed in easily, so should come out easy as well, once I can get an easy out in it. Exhaust is stock, and held in place with all the appropriate bolts. I use a locking nut over the flange to keep things tight. Prior to the upgrade, I had broken several of the studs and replaced them. I replaced with new during the upgrade to PREVENT this happening again, yet here I am.....
WHAT WOULD CAUSE THESE STUDS TO KEEP BREAKING with alarming regularity? Ive used all types, Harley, Aftermarket, Parts store, they all break off either flush, or just below flush with the head (on the coarse thread side of the stud) I dont over torque (snug plus a very little bit to keep from leaking with a small 1/4 drive ratchet, so cant really muscle enough to break a 5/16 grade 8 stud), WHAT AM I DOING WRONG HERE??
WHAT WOULD CAUSE THESE STUDS TO KEEP BREAKING with alarming regularity? Ive used all types, Harley, Aftermarket, Parts store, they all break off either flush, or just below flush with the head (on the coarse thread side of the stud) I dont over torque (snug plus a very little bit to keep from leaking with a small 1/4 drive ratchet, so cant really muscle enough to break a 5/16 grade 8 stud), WHAT AM I DOING WRONG HERE??
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Seasoned HDF Member
Joined: Apr 2017
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From: Globe AZ
this is the mount currently in the bike
https://www.denniskirk.com/v-twin-ma...rd/1401063.sku
Last edited by ScottinAZ; Aug 1, 2020 at 02:04 PM. Reason: added link to mount
Thread Starter
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Seasoned HDF Member
Joined: Apr 2017
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From: Globe AZ
`Ever use a torque wrench? Even when using the proper torque, do you use the proper sequence of tightening progression? Do you run the engine, let it cool and then re-torque the bolts to make sure everything is tightened evenly? Are you sure of the quality of your studs?
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Seasoned HDF Member
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From: Globe AZ
sorry, its my 2000 FLHTCU Twinkie motor. Stock style heads and factory exhaust
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From: Carlsbad, CA
Prolly caused by stress in the header by either, the motor bouncing around from bad motor mounts, or strain due to improper placement of hanger bracket. For the later, snug up the studs, loosen the support bracket, and run the motor a bit. Then snug up the hanger bracket.
