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Discussion Starter #1
Well ... when Vulcan #1 died, I went out and got another one. Had it one the road right away and was enjoying it.

Was changing the fluids, moving the accessories from #1 over to #2, and generally just having fun with it. Even put approx 900 kms on it on the weekend without any issues (other than a tank of bad gas ... still waiting to see if my girlfriend's ZN750 survived her bad tank).

Tonight, after changing the final drive gear oil, I thought it would be nice to move the engine guard from #1 over to #2 (since #2 didn't have one). The guard came off relatively easily, only a little "wiggling" required to get it off the bike, and the one bolt out past the exhaust.

Putting it on #2, that's where things went wrong. It became obvious right away that more than a little "wiggling" would be required to get the one bolt on past the exhaust. No big deal I thought ... I will just loosen off the header to give me some more "wiggle room".

Well ... you guessed it ... as I twisted one of the nuts, rather than loosen ... it broke the stud right off !!

Will have to call the dealer tomorrow and order some more new parts (studs, gaskets, nuts) and then see what I can do about getting the rest of the stud out.
 

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romeobravo172
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842 Posts
Sorry dude!!! I cheated on mine, think I have that same guard, you are talking about the right header exaust that has to be loosened to get the bolt behind off for the mounting bracket on the guard, the bracket that has the large nut on it, holds that piece to the guard. I said screw this and took a metal cutting wheel to the lower bolt hole and made it a slide on, can be done two ways, straight up from botton or from a 90degree angle. Makes install less painful, and cant tell it is any different!
 

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Discussion Starter #3 (Edited)
Well ... after going back down to the bike today, it became pretty obvious that there was no way I'd be able to get the studs out of the manifold with the manifold on the bike.

So off came the rad and fan (after draining it). Not really an issue, since I was planning to change the coolant anyways.

So with the rad off, I soaked the manifold studs and nuts with PB Blaster (several times) and left it to stew. Will probably hit them again with PB Blaster tomorrow (and maybe even once more after that) I really don't want to break off the ones going into the cylinder.

Maybe after a few days of soaking with PB Blaster they will come right off ...
 

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Maybe after a few days of soaking with PB Blaster they will come right off ...
it works miracles, i also like to torch them red hot and quench them in pb blaster, between a torch and the blaster you will get them. i hope! and some used manifolds probably aren't too much, on ebay (i sold some on clearance a year ago for $20 shipped). good luck man!
 

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Discussion Starter #5
PB BLASTER WORKS WONDERS !!!

3 of the four cap nuts on the exhaust manifold came off without any issues at all. The 4th turned just as easily, but it turned out the actual stud. Not a big deal ... it's easy enough to put in a new stud.

Now I just have to put the manifold on a bench and get the broken studs out (I left them soaking with more PB for the night).
 

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PB Blaster is some good stuff. I also use it to wipe down my forks. It also will help to keep the rubber seals and wipers from drying out and cracking.
 
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