Front exhaust mount bolt

[wally]

Thanx, I just need to figure out if movement/play on the muffler is normal.

[Route0766]

Yes, it is :)

[wally]

Anybody know the specs of the spacers on that front exhaust mount?

I have to start eliminating problems to figure out why I am losing bolts...

[jstav]

Here are the steps from the manual:
On the front muffler mount fastener, torque is applied to
the head and not to the nut.
4. Tighten front strap fastener and alternately tighten rear
muffler strap fasteners evenly till fasteners are tightened
to:
a. Front: Tighten around the muffler until snug.
b. Rear: 48-60 in-lbs (5-7 Nm).
c. Front muffler mount: 16-18 ft-lbs (21.7-24.4 Nm).
d. Front: 108-120 in-lbs (12-14 Nm). Back off fastener
two full turns and then retighten to 108-120 in-lbs
(12-14 Nm).
5. See Figure 2-115. Tighten the Torca clamp (1) to 28-
30 ft-lbs (38-40.6 Nm).
6. Tighten the front muffler mount to 16-18 ft-lbs (20.3-24.4
Nm).

In addition, I used a longer bolt for the front mount, and put an additional nut on, just tight enough to hold it like a lock nut. I jump over curbs, run down fireroads (mostly slowly), and haven't had a problem. Apparently, you are somehow putting undue stress on that bolt, probably because it has not freedom by being installed too tightly. If you have doubts about the actual bushing parts, you could order new ones from ASB. Cheers.

[wally]

Thanx, I followed it, sort of closely.

I wanted to see if I could get spacers made up locally.
When bolt tightened there is quite bit of play on the 2 spacers.

Is this correct or should they be fitting tight?

[jstav]

I do not think they should fit too tight, as they are more like bushings, rather than just a spacer.

[wally]

I tried to snap 2 quick pics this morning.

Looks grungy, but it is not that bad!

On the right side of bike the spacer sits deeper:


than on the left:


I also noticed quite a bit of space between the left side spacer and the actual mounting bracket.

Is this all OK?

Need to know, cause I ordered new ones through HD yesterday and if it is, I can maybe still cancel it if it isn't needed.

Thanx guys!

[wally]

Have some potentially good news so far.

After having lost countless high tensile bolts, I took a chance with a normal stainless bolt and lock nut.
Surprise! It is still holding up - for the last 3 days at least...:D

My mind said high tensile makes sense, apparently I was wrong... :p

[fishxb12]

The harder the bolt, the more brittle it acually is. Sometimes a softer stronger bolt is better than a super hard bolt.
Glad you are making some progress with your issue.

[wally]

Spoke too soon...

Heard the (by now) familiar sound of the chin fairing bracket vibrating a bit more than it did this morning.
And indeed - the nut end is sheared off again!

Plus, I followed instructions, torqued everything properly...

Waiting to see if the correct "Buell" bolt and nut will do the trick.

Also ordered new spacers.