TOPIC:

Hey guys. I was really excited to get my bike to turn over and fire for the first time in a year last weekend. However, I can't get the exhaust mounted up properly. Previous owner buggered up the exhaust stud mounts by over torquing them. I actually had to get part of the head welded back up where he cracked one of the stud mounts.

My roomate (used to work at a tool and die shop, so I trusted him) was convinced he could drill and helicoil the holes well enough, so I let him do it instead of having the same shop install them. Well, they're all crooked and don't line up.

Anyone have thoughts on how to get the exhaust studs lined back up for mounting? I can pull the helicoils out, but now the holes are crooked, so it can't really be fixed without going a size up to realign everything, and there just isn't space in there to do that.

If there's a way I can fix this in my garage, that'd be great. But I'm kind of expecting to need to take it to a machine shop. If I do, what do I need to have them do.

Also, if I need to take it to a shop, does anyone know of any good places around Cincinnati? I have a surprisingly hard time finding that sort of thing here for some reason.

I've been going through a lot of work on the thing over the past year. It's driving me nuts being this close to having it ride-able.

Perhaps a replacement head might be feasible?

Good Fortune!

to properly repair your head ,it needs the holes welded back up and the holes properly located and drilled and re-tapped.
other than that it's what patton ^^^^^^ said .
which truth be told is going to be the cheapest option if you need more than two or three stud bosses repaired.

leon

Replace the head. Have the replacement head professionally rebuilt as a used head will probably need some attention. New o-rings, exhaust gaskets, head gasket, & base gasket. May as well freshen up the bores & rings while the engine is apart. You may be able to get it all done for under $2,000. When done, maybe keep the room mate away from the bike, but send him the invoice along with a thank-you note. Ed

Yea, welding up the holes and retapping is kind of what I was figuring as far as repair options go.

I kind of hate to throw out the heads. They don't have many miles on them, and valvetrain wise, they're solid (I had a valve job done when I had the welding done). Looks like going price for heads is about $150, so between that and a valve job, I may not save any money going that route. Guess I'll find a machine shop and get a quote on the welding. If it's only a couple hundred worth of work, I may be just as well off fixing this one. Won't know till I ask.

I went through and redid the base gaskets etc while I had the original welding done on the head, so that's all in decent shape. I thought about doing rings, but everything in there looked almost brand new, so I left it. The bike only has a couple thousand miles on it.

Thanks for the input guys. I'll price out what it would take for a new head, and what it would take to get welded up, and see what makes sense.

i use these guys........... drag racers that have fair pricing quick turn around and do great work........

D & D Parts & Engine Services
6634 Vine St Cincinnati, OH 45216
(513) 761-1030

When buying a used head, make sure you have all of the correct camshaft bearing caps for that head, as they are machined to it. A lot of Ebay sellers try to sell the head without caps, and then the caps separately.