Full exhaust intstall..power duals, high output slip ons, big sucker, replaced gaskets on headers. Everything was going beautiful, had everything installed but not completely tightened up just in case I needed wiggle room. Went exactly by my service manual when spec tightening. Did first torque on headers to engine, no probs, on second torque before I got the click the bottom stud broke off on the rear of engine. No idea what the hell to do now. What happened with the torque? Help!

Trainz,

Well, the only thing you can do is take it all apart and drill out the stud and replace it and put it back together. In this case, if one stud breaks the others might too, be prepared. You already know this but only loosen or torque them cold, not hot after they have been heated up by the engine running.

I thinks Jims and Georges both make a guidance tool for just such an occasion.

https://www.toolsource.com/vtwin-mot...-p-111233.html

Georges Tool 340070, cheaper at 64.00 US.

Patience is required. Remember experience is the thing you need just before you gain it.


Good Luck

Calgaryglide

Throw away the torque wrench and just tighten by feel next time. After you ride the bike for a few hours check the studs to make sure everything is good.

I am an idiot, pretty sure I know what I did. Unbelievable!!

Trainz,

There are no idiots working on your own bike. Idiots are only found in government. There are only mistakes.

So I'm betting you set up the torque wrench wrong on the second torque sequence; confused inch/lbs to foot/lbs or foot/lbs to N/m metric.


Calgaryglide.

When i use a torque wrench, i always set the setting at a lower torque on the first torque to make sure the torque wrench is actually working right. Then i get withing 5-10 ft. lbs. or inch lbs and torque, then i go to the actual setting i want and finish up. I have done it this way for years because i have stripped a few bolts with a torque wrench going right to the torque setting. It just seems to me if you don't work up to the setting the torque wrench can and will over tighten sometimes.

He needs the old torque chart.

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Just ridiculous I missed this, and I was looking right at my service manual... in/lbs, not ft/lbs. Shoot me now.

ft lbs vs in lbs?

yep, you posted before i replied.... it happens. them studs can snap off even if you are using the correct torque. i had one break once, took it to the indy down the road. he used the jims tool on it, didn't have to remove the head. was pretty cool to watch, he drilled it out, then used a pair of pliers to pull the threads from the stud left behind. quick and clean.

Well, the head has to come off. We've made two days of effort to remove the broken stud and no cigar. I just hope to hell I havent ruined this bike.