I'm always nervous removing older exhaust manifolds and have wrung off a couple studs myself.
I think you will be better off with the studs rather than the bolts. The reason is there are two thread actions that can turn when backing off on the nut - the stud itself and the nut. If one is froze up, the other may just turn. Another reason is the next fellow who works on that bike won't be calling you off color names! When you do "ez" out the broken stud and want to use the "cap" nuts, be sure the exposed stud dimension is the same as the unbroken ones. That is an exact dimension when using the cap nuts.
Next time I pull mine, I'm going to use some "anti seize" on the exposed threads.
I don't understand specifically what you've got, but it appears one exhaust stud has sheared off in the head and the PO used what threads were available in the hole to screw in a bolt. Sounds like you also damaged the threads on a different stud. Either way, I would recommend replacing them both with the correct stud. That would mean you have to drill out and extract the broken one. That's never fun, but the good news is it's pretty accessible so if you take your time it should come out okay. Good luck and keep us posted.
got rid of that front fender today. plasti-dipped the airbox cover. oh yeah @rick. the stud hole with the hex bolt.. .there was nothing broken inside. PO was just lazy i reckon
+1 on getting a proper stud. I like to use proper studs in my motors because I know I'm using all of the available threads to hold that manifold in place. When the manifold regularly increases and decreases temp by a couple thousand degrees, I want to use all the threads I can get.
ok so now to find out the best place to order. local kawasaki takes three to five days to get em. figure id be just as well off to order them online. any ideas/part numbers?
Ace Hardware has a huge selection of metric bolts and nuts. I have found pretty much every one I've ever needed for my bike there, usually for less than a half dollar apiece.
got er set! runs wonderfully. removing the front fender changed the handling quite a bit though yeesh
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