| Author | Message | ||
     Orangeulius |
For those that haven't followed the troubles with my new to me 08 Ulysses, the saga continues. After taking delivery of it last January, I rode it for some time with a nasty vibration. Came to find out the front exhaust mount bolt that holds the front strap mount and the the strap were both missing. I replaced both and continued to have failures until my rear top header bolt sheared off in the engine. Clearly this was due to the extra stress caused by the miles ridden with no bolt or strap. ETENNULY was kind enough to help me drill the sheared bolt out which is a painful tale in it's own right. After rotating the engine, replacing the header bolt, and then bundling everything back up, I carefully followed the sequence to reattach the muffler and straps to avoid any undue stress. It's been a few months and a few hundred miles and I have snapped another exhaust mount bolt clean in the middle. Luckily i caught it early and was close to home so I don't think I caused any undue stress on the straps or header bolts. The bolts I am buying are supposedly grade 8 but I noticed they are mad in Taiwan. Other than finding a good American Made grade 8 bolt, what suggestions do you have? I looked through the bolt mount hole and it is nicely aligned with the mounting hardware so I don't think there is any undue stress from things being misaligned. After I get this nailed down I will work on the other left over problem from my engine lowering experience, CEL light, loss of speedo and tach. Think I stressed a wire in the harness during the engine rotation. This is my 2nd Uly and I am a gluton for punishment. If I can address these two issues, the bike is otherwise strong with under 15K miles on it. Help me Obi Wan BadWebbers, you're my only hope! | ||
| Tootal |
Your muffler is too low to the ground. You should have gotten an X!! Just kidding Mark! Made in Taiwan doesn't mean what it use to mean but it might be a bad bolt. How is your front motor mount? | ||
| Jasonb |
Made in Taiwan is about 30 times better than Made in China. I've been to both countries for work. China is the cheapest labor around. Taiwan is where you go for cheaper skilled labor, China is where you go for dirt cheap. And I mean cheap. | ||
| Orangeulius |
Hi Greg. You think the front motor mount could contribute to this? My buddy George suggested the bolts I have been using, I have had 4 sheer off mid bolt, may be too brittle. I'm checking into the differences between grade 8 bolts with slightly different compounds. | ||
| Tootal |
Do you know what grade the original bolt was? I only suggested the motor mount since vibration and flexing will eventually loosen and bend a bolt until failure. If you're using the same box of bolts maybe you could try a different brand. Find some made in the USA. | ||
| Pontlee77 |
maybe you tightened to much the header nuts? | ||
| Uly_man |
This all sounds very strange and you should not be having any problems. The only thing I can suggest is to "free off" the header to can bolt and rear mount bolt, until they are VERY loose, and then make sure the can fits snug under the engine. Nip up the front and rear can bolts and then tighten up the can to header bolt. Then tighten up to "hand tight" the front and rear can bolts. Use HD OEM bolts ONLY. If that does not work leave the front engine mount bolt off/out, heat the bike up and see if its position moves. | ||
| Orangeulius |
Thanks for the suggestions. I'll try a bolt from another provider, watch that I dont overtighten, and follow the sequence Uly Man suggested. Now all I need is some warmer weather! | ||
| Uly_man |
"I'll try a bolt from another provider" I would suggest you get the HD one. At least you will know it is the right one for the job. A dealer should be able to post it to you. | ||
| Tq_freak |
Could the header be tweaked at all? | ||
| Reepicheep |
Check all the other motor mounts as well, including the one for the rear head to the frame under the airbox. | ||
| Orangeulius |
Well we may have found the variable. The bolt is 5/16-18. Some 5/16-24 lock nuts got in the bin with the 5/16-18 nuts. They were oddly tight getting started but I thought this was ok simply because they were lock nuts. This means I was overtorquing the nut which compromised the bolt. Now running with the proper size nut for the bolt and have it properly tourqed. Time will tell. Knock on wood....(replace "wood" with "my head".) | ||
| Arry |
That's a lock nut that ain't com'n loose! | ||
| Etennuly |
Now running with the proper size nut This is something I always recommend.  Every time.  | ||
| Tootal |
Does that nut have a B.A.W.?  | ||
| Etennuly |
It did for a while on the previous Uly. I have mine on. |
