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Header Bolt Threads Are Junk

GabrielGoes

GabrielGoes

Forum Mentor
SO im trying to get these 8 bolts back in, im using anti-seize and some are just really starting to cross-thread. im thinking guys im going to buy 8 brand new bolts and put them all in whether the GS likes it or not... any ideas before i destroy my head? edit:3 of the holes are putting up somewhat of a good fight- nothing is (completely) ruined YET...
 
Don't use bolts, use studs. Suzuki was cheap but that doesn't mean it's a good idea to repeat their mistake.
 
studs? what do you mean i dont know if i understand, the head has 8 holes that need 8 bolts to go inside them, its not like theres 8 sticks sticking out. i'm probably not understanding you... anyways i dropped my bike so ill need the parts i was gonna send you
 
A stud is like a bolt with no head. You put the stud more or less permanently into the head, then use a nut to hold the pipes on. That way when you take the pipes off, the nuts are turning on the steel studs, which stay in place in the head, and you are not wearing out the soft aluminum threads in the head. If your threads in the head are too far gone to thread the studs into anymore, you can use some Locktite to hold the studs in. Good studs even have an Allen head socket in the end so you can easily hold it from turning when you put the nut on. You don't want the stud bottomed into the hole, go in until it stops and come back out a turn, it's a lot stronger that way.

Exhaust studs from a certain Subaru have the same thread pitch and diameter, and are about the correct length for our engines. Sorry I can't remember exactly which model, but you should be able to search it. Also NAPA sells a stud kit that works.
 
You get 8 1 /3/4 inch or 2 inch exhaust studs like that go onto the car headers. You put them in the head of the motorcycle and you install the exhaust with nuts and washers on the studs. Use high temp locktite on the studs. The ideas is to leave the studs in permanently as to not tear up the threads any worse. You simply take off a nut and washer if you want to remove or replace the pipes. Take a wire and put to the bottoms of the bolt holes in the head, measure the collar or flanges on the pipes..add the two for an average length of a stud youll need.
 
Yeah, never re-use the exhaust bolts from a stock GS!
They are notorious for breaking left and right!

Im actually surprised you got the stock ones off, without snapping them.
 
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