update on new exhaust.. cracked mounting screw

So I got the old stock exhaust on my buke. Got it to fit with a few minor changes to how it mounts under my foot pegs. Sounds great.

I noticed one of the pipes was leaking where it connects to the motor, I went to tighten it and bam, the bolt that the headers connects to snapped. It's now only being held on by 1 screw and the housing is uneven.

Does anyone know if those little skinny bolts can be replaced? I have checked partzilla etc and can't seem to find it.

Anyone ever had this happen to them?

Please help us help you. In your signature line where you state "Strap up, Sit down, Ride Smooth..... " add the year and model of your motorcycle. Kawasaki made KZ models from 200cc to 1300cc and within each range there were numerous models. If you add your year & model to the signature line you won't need to remember to describe it in every posting and we won't need to try to guess what bike you have. Thanks. Ed

For clarification, the bolt I am talking about is the bolt that part number 92016 screws onto to tighten the headers to the motor

Thanks Ed, thought I put that info in last night. Updated

Are your referring to the header stud that is fastened to your head? I have a 77 KZ1000 and and replacing the studs with bolts due to my new header configuration. I'm more than happy to mail you a couple if they are the same size.

This is what I'm talking about. Sorry I'm not a mechanical person so pics are easier for me

According to Kawasaki.com the studs that screw into the head are still "Active" (see image below) so any dealer can order them. Partzilla.com lists them at $1.96 each (see link). I would HIGHLY recommend that before you attempt to remove the broken stud you first soak it with Kroil for 2 or 3 days. That should help break the bond between the stud and the cylinder head. After soaking it, assuming there's enough stud left to tightly clamp Vise-Grips to, it should unscrew from the head. If for some reason it seems to require excessive force to unscrew you may want to take it to a machinist rather than take the chance on cracking the cylinder head. Ed

www.partzilla.com/search/?q=92004-066&x=14&y=8

Thank you soo much ed. I am ordering now. I was looking in the wrong spot on zilla.

kaw-a-holic wrote: Are your referring to the header stud that is fastened to your head? I have a 77 KZ1000 and and replacing the studs with bolts due to my new header configuration. I'm more than happy to mail you a couple if they are the same size.

I believe the studs on the '77 KZ1000 are 8mm x 30mm, but the studs on the KZ550 are 6mm x 27mm. Ed

Alright so a final question. Would I be fine riding it a mile to and from work everyday till it comes in? It doesn't seem to be leaking and is staying secure when I give it throttle. I don't wanna damage the bike and can walk if necessary.

Thanks

That's a little hard to predict - it may or may no hold. If mine I think I would let it sit until I could replace it just to be positive I didn't damage anything. Ed

Did the stud completely sheer off or is there some of it sticking out?

Get some Kano Kroil penetrating lubricant. Or Liquid Wrench penetrating spray lubricant. Apply the penetrant & let it sit overnight. Apply some more & let it sit. Then run the engine to warm it up. Apply some more penetrant & let it sit overnight. You get the idea. Also, tap on the stud using a wood block & mallet - but only if you can do so without damaging the stud.

The stud may be difficult to remove, so don't do anything until you use the penetrant. Give it time to work. Patience is a virtue in this case. Penetrant. Time. Heat. Vibration.