| Author | Message | ||
     Osufz6 |
Picked up a 2008 with 3600 mies two months ago. Ten minutes from my house after a 1500 mile trip I notice it had become louder. The front header pipe cracked completely.Ever happen to anyone else? The warranty expired 6 weeks ago. The service manager contacted HD and they agreed replace the part. I pay the labor. Really enjoy the bike. | ||
| Mikef5000 |
Does it have an aftermarket or re-painted exhaust? Mounting the muffler improperly can cause added stress to the header, which can lead to cracks in the pipe, or broken studs. | ||
| Osufz6 |
It is all stock. I did wrap the exhaust without removing it. The HD service mgr. said that did not contribute to the failure. | ||
| Reepicheep |
Good for that dealer... care to say who they are so we know another "good one"? Given the circumstances with Buell and the wrap you had on it, it would have been very easy for them to decide not to cover the cost of the parts. If it were my bike, I'd be looking for a broken strap or lost front exhaust hanger part to make sure it doesn't happen again... | ||
| Yool |
I just posted this in B,B&D, I'm not sure the metal thickness on the headers is very constant or predictable. Some guys get cracks across the header, mine cracked along the header. Even the paint I sprayed on the headers has not burnt off in the way I expected  | ||
| Osufz6 |
The dealership that's doing the work is AD Farrow in Columbus, Oh. Interesting to hear about another failure. In nearly 30 years of Japanese ownership I never had a repair like this. I would enlist the help of a friend who is capable of doing the work but the only way I get the part is with dealership labor. With no warranty it seems reasonable | ||
| Reepicheep |
Thanks! They are close enough that I could use them if necessary. I'm annoyed at my two local dealers, neither of which stocked a front exhaust clamp. | ||
| Osufz6 |
There's more. Received a call from the dealer this morning. It appears one of the studs on the rear cylinder snapped off. Another 3-4 hours labor. The 1/2 charge for the rider comfort kit reflash seems like quite a deal.. I did ask the service manager to contact HD to plea on my behalf. We'll see what happens | ||
| Speedfreaks101 |
I don't want to hijack but I would like to know if the exhaust pipe has ever cracked on a pre 2008 model? I know that there was a change in shape and also material. This makes me curious if this might contribute to this issue. I am not referring to the broken studs only the cracked header. | ||
| 1324 |
There's more. Received a call from the dealer this morning. It appears one of the studs on the rear cylinder snapped off. Another 3-4 hours labor. The 1/2 charge for the rider comfort kit reflash seems like quite a deal.. I did ask the service manager to contact HD to plea on my behalf. We'll see what happens More than likely, the exhaust stud broke when they removed the header. If so, they should have the tools and parts on hand to fix. 3-4 hours sounds high, but what do I know....I don't take my bike to the dealer. Good luck. | ||
| Reepicheep |
If I did the engine rotation by the book, I probably couldn't do it in 3-4 hours, and that assumes I have the Jims tool and it all goes well. The two times it went poorly for me (one broken easy out, one broken tap) it was more like 8 to 16 hours.  | ||
| 1324 |
Agreed. But the basis of my comment was that the dealer has to rotate the engine to change the header. Since the dealer is already at that point, the only labor should be to remove/replace the stud. | ||
| Reepicheep |
Ahh! Gotcha. "Book Rates" always bugged me... seems like it oughta be illegal. | ||
| Osufz6 |
There's more... received a call that the new exhaust was installed but the bike was "throwing a code" (check engine light). I explained the light was not on when I dropped it off. a tech wanted to bill an hour labor for diagnosis. I received a call later on and was told it was some sort of motor that controls exhaust flow. Dealer will eat the part. 1/4 labor for me. Part, however, is not in stock. | ||
| Gunut75 |
Exhaust valve? I would have told them where to stick their 4 hrs too! Maybe they forgot to hook it up when they put the exhaust back on. | ||
| Skinstains |
The more I read stories like this the more I think I should open my own shop. You know damn well that anybody with any sense could've remover that header without busting that stud. Don't even say it Froggy... | ||
| Reepicheep |
I wouldn't be suprised that a cracked header ended in a broken stud, or vice versa. I doubt they broke the stud pulling the header. And they either forgot to hook the exhaust back up, or were in "anger mode" when pulling the old one apart and tore it up getting it off. Having pulled the can on my 9sx a bunch of times (no servo), the first time I pulled the Uly can, I was surprised to see it dangling there, until I remembered the servo. |
