Hi guys,
after removing and re-fitting the Jardine for repack, i find that the front manifold/header is now blowing a little.
The nuts seem tight but there is a bit of play in the exhaust, ie the pipe will move in and out of the manifold a few mm.
Is this common for them to blow from here if the exhaust has been worked on?
What is the set up inside the manifold? Gaskets? O Rings? Or some other kind of seal?

I fear that if i try to undo the 2 retaining nuts on the manifold that they will round on the stud or snap the stud. Again is this common and in experience are the snapped studs easy to remove with "easy outs"?

Many thanks in advance

Pete

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So Mote it Be

Sounds like you need new exhaust gaskets. They are concave rings of metallic weave.

Studs do break, make sure the exposed thread is clean and apply some oil. You might also what to try and remove the nut/stud with the engine hot. The stud is 5/16 UNC where it goes in the head, but has a larger minor diameter to act as a thread lock. Although people have had the stud come out when trying to remove the nut, my experience is that the stud is more likely to shear.

Easy outs are a no no, they will break then you will be retracing your steps with a Dremel. I have drilled them out on a milling machine before to get the hole position and angle correct. prefers spark erosion. You can also get a tool from Jims which has a drill guide. Yourguitarhero had one that was donated to UKBEG, I think babybadger has it, so it may be worth PMing him if you have problems. Only issue with this tool is being able to get enough load on the drill to cut effectively.

When you put it all back together, use 5/16 UNF AS silver plated nuts, cheap off EBay, self locking and corrosion resistant.

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08 Specialized Langster

I had it , out in tenerife, but posted it back with all the taps , but pash never received it ..... it was too late to go for the compensation....., they are available on eBay cheap enough...

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Buell X1 lightning 2001 in white

Probably the gasket but my old headers had a problem that gave same symptoms. The engine end of the header is double thickness to allow a step for the retaining circlip to do its job, ie pull the header tight into the gasket. Mine had fractured right at the very end of the header all the way round leaving the outer double skin loose and hence the header would move a few mill in the manifold. Apparently it can be welded, I temporarily bodged it with chemical metal while saving up for new headers.

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Buelling is exhillarating
But downhill bike racing is so terrifying it makes your arse grow teeth