Exhaust studs or bolts.

[Guest]

The engine that I got in the 82 Katana (750) project bike didn't have any exhaust studs in the head and the spare engine is missing a few. Can anyone tell me the size or thread pitch i need to find and the nut size as they're missing too.. Also is it possible to use a cap bolt in lieu of a stud?

I always find thread pitch and bolt sizing to be confusing and its time consuming trying to figure what fits what. I spend hours in the hardware stores sorting through things especially metrics which seem to come in several different pitches in the same size and that's not even talking grades which confuses it further.

Anyone know of a turotial on this stuff?

Cheers,
Spyug.

[doctorgonzo]

My model has bolts. Standard on all these bikes is (I think) M8 X 1.25. For bolts the length is 40mm (again I think).

[hikermikem]

My model has bolts. Standard on all these bikes is (I think) M8 X 1.25. For bolts the length is 40mm (again I think).

My recollection from my 750LX was: M8x1.50, 35mm long - OEM bolts to hold a stock exhaust on...

As doctorgonzo sez, "I think"

[doctorgonzo]

Search for the link, if you look the part up on alphasports, the bolt specs are imbedded in the suzuki part number. 1.5 pitch would be weird I think, they make 1.5 for M10 bolts, and they may make it for M8 bolts, but 1.25 is "standard" pitch on M8.

[hikermikem]

Search for the link, if you look the part up on alphasports, the bolt specs are imbedded in the suzuki part number. 1.5 pitch would be weird I think, they make 1.5 for M10 bolts, and they may make it for M8 bolts, but 1.25 is "standard" pitch on M8.

The p/n for the exhaust bolts: 01500-0835B

How do you decipher that number?

[doctorgonzo]

The p/n for the exhaust bolts: 01500-0835B

How do you decipher that number?

We'll have to find the thread on it, or someone who remembers for sure come along, but from memory, that means you are right, that number means

M8 1.50 pitch 35mm long.

[doctorgonzo]

http://www.thegsresources.com/_forum/showpost.php?p=825639&postcount=5

This post actually indicates that Suzuki DOES use standard pitch, so the bolt (per that number) would be M8 X1.25 X 35mm, but don't hold me to that pitch.

[Turtleface]

Go with studs if at all possible. Easier on the threads in the engine block, and usually makes installing the header easier. A big plus if you need to drop it for maintainance.

[hikermikem]

http://www.thegsresources.com/_forum...39&postcount=5

This post actually indicates that Suzuki DOES use standard pitch, so the bolt (per that number) would be M8 X1.25 X 35mm, but don't hold me to that pitch.

I have a tap at home that I used to chase those exhaust header threads, after i had to remove a 2 broken bolts (another l-o-n-g story).

Unfortunately I won't be home 'til Sun evening, so I can't verify the thread until then.

[doctorgonzo]

I have a tap at home that I used to chase those exhaust header threads, after i had to remove a 2 broken bolts (another l-o-n-g story).

Unfortunately I won't be home 'til Sun evening, so I can't verify the thread until then.

Mine had 3 broken bolts, one i never could get out. That was the starting point of swapping out for the 1100 head (with header bolts LIBERALLY coated with anti-seize).

[salty_monk]

I think I'm going to move to studs as I have to drop the header each time... either that or I'm going to put in a second drain plug off to the left side.

Dan

[hikermikem]

I think I'm going to move to studs as I have to drop the header each time... either that or I'm going to put in a second drain plug off to the left side.

Dan

You could always turn the bike upside down & drain the oil thru the filler hole

[doctorgonzo]

You could always turn the bike upside down & drain the oil thru the filler hole

Build a vacuum pump that sucks it out!

[salty_monk]

Often thought about that but I don't think you'd get anything past the clutch basket - not only that I also have to remove it to get to the oil filter....

Why Suzuki didn't follow the Z1's example with the filter I don't know...

[tkent02]

Go with studs if at all possible. Easier on the threads in the engine block, and usually makes installing the header easier. A big plus if you need to drop it for maintainance.

+1, Suzuki used bolts as they are cheaper and they will outlast the warranty, but studs are a much better long term method of attaching the headers.