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Exhaust nuts/studs Exhaust nuts/studs
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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 7 Apr 2008
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Exhaust nuts/studs
I always have trouble with exhausts studs rusting then breaking when I try to remove the exhaust on my XT, even after replacing with new genuine studs and nuts 6 months later a stud will snap when I try to remove the exhaust.
I have just seen a Honda XL600 that had chrome domed nuts on the exhaust studs. They looked like 8mm XT is 6mm stud.
Do you think domed nuts would help ?
Is it possible to fit 8mm studs in the XT600 with out causing other problems.
What would be the best studs to use?
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  #2  
Old 7 Apr 2008
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I had similar trouble recently....Two of the four snapped and one of the snapped ones had to be drilled out. I upsized that one to 8mm without problem. Even though I fitted a stainless header, I still intend to re-apply copper grease once a year, but hope the exhaust will outlast the bike now!

DC
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  #3  
Old 7 Apr 2008
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My Yamaha dealer tried to remove the factory exhaust, because it had holes in it. It took them 12 hours of labour because all 4 studs just snapped. They used burners and whatnot to take the exhaust pipes off. Then they put it all together again, stainless pipes and such, and then we discovered they dropped a piece of metal in the cylinder... They paid for the entire repair. Now I take the pipes off every month, just to be sure.
Stainless and aluminium just isn't a good combo.
My advise: don't use an XT in wet, muddy conditions.
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  #4  
Old 7 Apr 2008
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Good advice...But dont think your troubles are over if you slacken the studs now and then. The problem I had was that the 'shoulders' on the exhaust remained tight against the engine in their sockets as the old exhaust was rotten. Access to remove them was difficult and it took a weekend of swearing to get them out of the block.

DC
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  #5  
Old 8 Apr 2008
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Brass nuts might work better than steel as they ought to fail before you can apply enough torque to break the studs. However, the only brass nuts i've found have been no more than 5mm depth.
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  #6  
Old 8 Apr 2008
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"However, the only brass nuts i've found have been no more than 5mm depth."
Bigger ones I've never had a problem getting, but usually from a car parts place.
firewall forward

But isn't there something about brass nuts and cold weather?
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  #7  
Old 8 Apr 2008
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studs
My answer to this is to just make the brass nuts any size that I want. I can do that as I have a pretty complete maching shop but if you bought brass stock in hex of the size that you needed any machine shop could cut them and thread them on a lathe with a tap for little money. At least compared to 12 hours of cussing and swearing and wrecked blocks and things.
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