| Author | Message | ||
     Athens_blaster |
Hi, I've had this problem happen three times now. On the exhaust that came with the bike it completely separated at the weld of the exhaust and the muffler, just cracked the complete way around. I had it rewelded and it then it cracked at a completely separate spot in the exhaust pipe and then proceded to break a complete 4-inch piece of my exhaust pipe out. I bought a new one on ebay for about $45, and put it on, within three days it had cracked at the SAME exact spot that the previous one had cracked it. If anyone has any ideas throw em out, Im out of em and frustrated with the whole situation. Thanks all | ||
| Blastronomer |
Hmmm. I'm a rookie, but it's got to be the mounts, right? But I'm sure you already thought of that. You are talking about a stock exhaust right? PS I used to live down the way in Rutledge and I'm a huge Widespread Panic fan. Athens is probably the coolest town in Georgia. | ||
| Swampy |
Stock exhaust, yuck! My crystal ball says you will continue to break exhausts. after you get it all welded back together, replace the rear mounting strap, the front mount and the exhaust gasket, then start at the front and snug up the flange, snug up the rear strap and then tighten everything front to rear. Or put a straght pipe on it....that stock exhaust is crazy heavy... | ||
| Johnnymac |
Hey, Ben. I haven't been on the site for a while now but I still get emails from the Blast forum. Your issue is just like the one I had. I bought my '07 Blast new in '08. In the time I had it the exhaust was replaced under warranty 4 times. In between replacements I had it welded 3 times because I couldn't wait the 2 weeks to a month it took each time for a new OEM exhaust to be shipped to the dealer. The last few times it broke a day after it was installed...literally. I'd drive out of the dealer with a new exhaust and the next day on my way home from work with just over 70 miles on the new exhaust it would crack open and I'd be back at the dealer the next day extremely pissed off. The guys in the service department were great to me. They checked and replaced everything they could each time it failed. Motor mounts, isolators, hangar hardware, etc...they could never find the cause. Finally, after the 4th replacement broke in just one day, they decided throwing a new exhaust on the bike every other day was not a solution. They called H-D to speak with the engineers and corporate techs and described to them what was happening. Apparently it was not an issue unknown to them. The engineer asked if I did a lot of highway and/or high RPM driving. My guy said yes, that I commute 80 miles/day and put over 21k miles on the bike in less than 2 years. The engineer said he figured as much. They had discovered that the Blast can create a harmonic vibration at sustained highway speeds which will cause the exhaust header to basically shred itself and crack. He also said that it is a design flaw and there is no real fix for it. The Blast is no longer in production so they will not make any effort to re-engineer the exhaust. H-D corporate offered the only solution they knew of and that was to install an aftermarket exhaust at their expense. Needless to say I jumped at the opportunity. Normally they installed the V&H SS2 since it was the cheapest. I told my service manager that that pipe was unacceptable to me since it requires repacking every 4000 miles and I was not going to be repacking my exhaust every 3 months. I told them I wanted a Jardine with a quiet core insert. He looked up the cost at around $350, called H-D, and they approved it. 3 days after approval I had a brand new Jardine exhaust on my bike bought and paid for by H-D! Best thing they could have done. Pipe didn't break and I was in love with the bike all over again. | ||
| Johnnymac |
Now for the bad part (or good part as it ended up for me). About a week after I got the Jardine installed, I was on my way to work when I hit a dip in the highway and it felt like I lost the rear tire. I pulled the bike over to find the tire fine but the back of the bike was laying on the tire. Closer inspection revealed that all 4 bolts on the rear engine mount had sheared off at 70mph. Fortunately for me I did not lose control of the bike as it could have been a horrendous thing. I called my dealer and they immediately sent out a trailer to pick me up. We got back to the dealer and all they could do was look at it and shake their heads. My bike was going to be out of commission for a week or two while they inspected and repaired the damage. Having had enough, I called H-D corporate offices and stated that after 4 unresolved attempts to replace the factory exhaust issue I had no choice but to declare "Lemom Law" on them. This got me some action. I got a case number and was told that this would be investigated ASAP. I then called my friends at the dealer, informed them of my action and asked what the normal procedure was at this point. They said that the investigator would request copies of all my repair history, visit the dealer to speak with the service manager and technicians, then render a decision. If they decided it was a Lemon issue they would buy the bike back from me. A week later I got a call from my dealer stating that H-D agreed to buy my Blast back from me for what I paid for it. Not just for value of the bike but including the accessories and sales tax! Instead of losing my ass on a new blast purchase, I ended up being able to pay off my loan and have some equity left to put down on a new ride. A day after that I rode home on an '09 883 Custom, the bike I should have bought in the first place. I am loving every minute of it!! The Blast felt like a child's toy compared to my Sporty. It's even easier to ride fast than the Blast was and I am able to take corners as fast or faster with half the effort. Hard to believe but true and I was no wussy on my Blast. My foot pegs were ground to stubs, the exhaust had it's share of scrapes and I had dragged the pulley more times than I wish I had. Racking up the miles on the Blast was tiring and stressful. A good bike for around town but not for any kind of real commuting. It served me well but it honestly won't be missed.  | ||
| Ezblast |
The Experience is yours, but that crack about the 883 being better than the Blast is such a crock, that I won't even answer it with an insult. As for commuting the Blast does fine, your opinion is just that - nothing more or less. For every opinion like yours I can put up 100 contrary. So take that for what it is worth - reality wise. Personally - either of my Blasts dusted 883's pretty regularly - especially on the Alice runs, so I really question the whole thing above, but I'll let it go - it is after all only your opinion and as such its ok by me. EZ | ||
| Johnnymac |
EZ, you question the whole thing above?? Aside from my opinion on the driving experience between the two, which is my opinion and no better or worse than your opinion, what exactly are you questioning? The fact that my exhaust broke repeatedly? the fact that my rear engine mount broke? the fact that H-D has seen the issue before and admitted they have no fix? The fact that they bought me a Jardine exhaust? the fact that they bought my bike back under the Lemon Law? Or is it the fact that they bought it back for every penny I paid for it?  | ||
| Johnnymac |
One thing that I recommend you check, Ben, is your rear engine mount studs. I found it hard (impossible actually) to believe that all 4 of my rear mount studs snapped off at the same time and am convinced that 1 or 3 of them were already broken before it completely failed. I could be wrong on that but I think that the rear mount is the one thing that they may have neglected to diagnose or notice when they were troubleshooting my exhaust issues. As I said earlier, they replaced all of my front mounts and isolators as well as the exhaust mounting hardware and still the cracking continued. I am thinking that the rear mount may have been loose enough, at least during the latter breaks where it would break in a day's time, to have contributed to the breaks. Carefully inspect your rear engine mount not only to protect your exhaust from possible future breaks but also to protect yourself from having the whole works collapse on you while riding.  | ||
| Ezblast |
No - If you read my post closely, I only question two things - 1) no way the 883 is better than the Blast at anything but maybe cruising down a straight line for very long periods, and 2) not in this life time or the next will it ever handle better than a Blast. The rest is what it is. EZ | ||
| Gearheaderiko |
Johnnymac: thanks for the insight on the exhaust. While I agree with EZ that there is no way the 883 handles better than the Blast, its your opinion, your bike and you're entitled to it. Comfort and confidence is key in what you ride and if the bike fits you better, you'll likely ride it faster. If you limit top speed, I could take my {*offensive HD named bike deleted*} around the racetrack faster than I could take an 1125R. One bike is just way more comfortable for me to ride. I've also seen some guys shred on some very unlikely beasts! | ||
| Blastedrat |
We had the same problem with a Blast breaking new replacement exhaust pipes at the dealership. After comparing old to new, we found that the head pipe section is welded on at a different angle, and doesn't let the exhaust mount up properly. We are still waiting for a correct replacement from the factory for a customers bike. | ||
| 2hrcommute |
Blastedrat, I'm getting my header replaced at the muffler shop as we speak. Can you describe the proper weld angle or better yet pictures? Thanks | ||
| Rusty7983 |
i love to ride my blast. i ride every chance i get. the exhaust was broke when i got it, i mig welded it back. i drive it 100 miles a day to school( temporarily unemployed). and it gets 65 70 mpg. | ||
| Aflyingman |
I have had the same problem numerous times! In the 2 1/2 years that I have owned my Blast: The front motor mount pulled out, leaning the engine on the tank and melting a hole in it. - Factory replaced under warranty. The exhaust has blown apart 4x, twice at the head and twice at the base of the neck. - Factory replaced it every time under warranty. On the last replacement, the factory had the top end of the motor rebuilt with a new head, as they could not get of the 5 factory systems that they ordered to attach to my original one. Three days later it blew apart again; this time out of warranty. I could feel that vibration this time. It was so intense that I had to remove my feet from the foot pegs; no vibration in my hands and not much in my seat, but it felt like I was almost being shocked through my boots. I could not get it to go away by varying my speed. It started while I was accelerating onto the freeway when I hit about 65 or so. It remained through 70 and down to 55 for about three minutes and then disappeared. 20 minutes later, the exhaust blew. No love from the factory this time. How do people race these things without blowing them apart? What exhaust system will stand up to freeway riding? Looks like I need to check my rear mounting bolts. I commute about 1000 miles per week. Any suggestions as to how I can get a Blast to do that for more than 2 weeks at a time? Love the bike, want to keep riding it, not storing it. Buying a V&H today. | ||
| Ezblast |
What you want is the V&H packed tight with hi temp boiler/oven fiberglass insulation - http://www.industrialinsulation.com/blanket_roll_i nsulation.htm EZ | ||
| Gearheaderiko |
You obviously have a problem that is unique to your Blast (and maybe a few others). It could be your riding style (no offense) or something is wrong with your engine, frame or mounts in between. I can say a Blast is quite smooth at 7500 rpm (1000 above stock redline) and, imho, they smooth out the higher the rpms go. For them not to replace it again, gratis, they would need to explain exactly why you keeping breaking the exhausts and why its not a problem with the bike. It sure sounds like a lemon law case and I believe CA is very liberal in that department. 2008's may also have an updated engine mount or they updated it during one of the repairs and it can make the vibrations worse. But the engine, in some regards, wouldnt know the difference. If you have not done anything to improve the engine performance of your bike, now would be the time (unless you are going to pursue warranty/lemon law issues). New exhaust and carb tuning (jetting, adjustment, needle shims) as well as checking the timing and primary chain adjustment may go a long way to smoothing things out and possibly eliminating your problem. I can tell you that the stiffer you make the engine mounts on the Blast, the more unbearable it can become to ride. But it shouldnt affect the engine in any way I can think of. | ||
| Gearheaderiko |
PS The exhaust we ran on the racebike extended out pass the rear tire (it was looong). It was also the "fragile" White Brothers. We only broke one small inconsequential exhaust mount that I never bothered fixing. | ||
| Aflyingman |
Thanks for the help all. I have wondered if I ride it "wrong" and asked the shop if that was the case. They said that I was riding it fine and regardless, it should not be doing what it was doing. The shop has been awesome by the way. If you ever find yourself on I-5 in Lathrop, Eagles Nest is a great shop. I installed the V&H and test rode it a bit. I don't have it packed with anything extra yet and I love the sound. Definitely need to ride with earplugs on a long run. First real ride was this morning. Started with back roads for the first 50 miles or so, then the freeway for the last 50. We will see how she does... Most of my riding is on freeway and every exhaust failure is on the freeway. Is 70 too fast for 2 hrs at a time? Anybody know how to install a tach on a Blast? If the engine will stay together after 6500 rpm (factory redline) how do you bypass/disable the spark governor? Looking to jet and install a K&N next. On the design of the V&H, I think it is far superior to the stock muffler. Weight and sound aside, the fact that it is a slip-on system is going to make it last longer on this bike. The exhaust pipe is hard mounted to the head and the crankcase and the muffler is hard mounted to the frame. This is the same way that the OEM muffler was installed too. The major advantage that I can see here is that the engine vibrations and the frame vibrations are allowed to be independent of each other now. On the OEM muffler, there was no "fail point" or give in the design so if the engine was vibrating faster or slower than the frame, that energy was absorbed by the muffler. With the V&H the engine vibration and the frame vibration are allowed to be a bit off because the exhaust that is mounted to the engine is allowed to slip into the muffler that is mounted on the frame. Seems like Buell should have thought of this one to begin with. Oh well, thank God for private enterprise and the after market. | ||
| Crackhead |
humm,... look again, the exhaust is only mounted to the motor. It sounds like you might have a bad rear motor mount or the bolts to the tie bars have come loose. The only way to get higher revs is to replace the valve springs and the ignition. | ||
| Buellistic |
The FACTORY SERVICE MANUAL "MUFFLER INSTALLATION" is such a "URINE POOR" explanation is why everyone has a "BAD EXPERIENCE" with the OEM muffler set-up !!! CORRECT WAY to assemble is "REAR" to front "HAND TIGHT" ... TORQUE "FRONT" to rear ... Use GASKET,exhaust port(17048-98) "BECAUSE" the GASKET,exhaust port (65324-83A) is "FECES" !!! P.S. It does not say to replace anything(BAD) except the GASKET,exhaust port or to check anything excessively worn ... Iam Noone' (Message edited by buellistic on February 08, 2011) | ||
| Gearheaderiko |
The exhaust only mounts to the engine. The muffler mounts to the kickstand frame which is mounted to the engine. Its recommended that you use the stock rubber mount at the front crankcase mount. 70mph or faster is fine on the Blast for extended periods of time. See how long this exhaust lasts. If it too fails quickly, then there is a problem somewhere else other than the exhaust. It will need to be repacked eventually, certainly by 10,000 miles as once the packing is gone the muffler deteriorates quickly. If you havent re jetted, you must with the new exhaust. 170 or 175 main jet. 45 slow jet and 2 shims on the needle (general recommendation and pretty close to what you'll need). The stock cams really dont perform after the stock redline and power drops off dramatically. Its a lot of work (kinda) to run the Blast past stock redline. Worth it (imho), but not a simple task. | ||
| Buellistic |
70 MPH or better works much better with an XB12 motor sprocket on your BLAST on the Interstate ... 1.75 to 1 rocker arms works quit nicely with the OEM cam and OEM ignition module ... Iam Nonne' | ||
| Ezblast |
I'll bet it does - lol - EZ | ||
| Diozark |
Wow, that guy had a blast that failed miserably. Sounds like neglect. I am customizing two Blast bikes, one I picked up for 1200, with 600 miles on it, The other 2200, with 3200 miles and rode it 1036 miles in Three days. It's not a touring bike, lol, but its smooth, I like the ride better than the 48, but gotta do something with the seat and the exhaust, the first bike I chopped off the muffler and turned the header horizontal, sounds good, just have to shape the end, maybe slash cut down and out. Cool Bike, wish they were still building them. |
