Replacement of OEM Bolts with Stainless Steel Bolts
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  1. #1
    Resident Guru JC-SuperJet's Avatar
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    Replacement of OEM Bolts with Stainless Steel Bolts

    Recently read the following: "Watch which bolts you replace with stainless on the motor as you cant get stainless bolts to the correct torque setting, that's why they use plated high tensile bolts "

    Is this correct? Why? Something to do with Galling?

    Seeing that a lot of Riders replace the ugly rusty Factory Pipe Head Bolts with shiny Allen Stainless Steel Bolts, and also, I hear about many Exhaust Manifold bolts vibrating loose in Conversion Skis (e.g. Blaster 1100, SXR 1100),
    I'm interested in knowing.

  2. #2
    PWCToday.com Is My Home Away From Home mcn6's Avatar
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    Re: Replacement of OEM Bolts with Stainless Steel Bolts

    Head studs are the only fasteners I have had issues with as far as stainless bolts or studs stretching and/or breaking. I have heard of the head pipe to manifold issue, but have never experienced it myself and I have used plenty of the A/M stainless cap screws in that application.



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  3. #3
    Resident Guru JC-SuperJet's Avatar
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    Re: Replacement of OEM Bolts with Stainless Steel Bolts

    Do you Helicoil the Exhaust Aluminum Holes (like the Aviation Guys) and then lubricate stainless bolts with anti-seize?

    I usually only Helicoil when needed and use the OEM Bolts with Loctite.

    For Reference, I found a nice Bolt Torque "Kalkalata" that considers both the Bolt properties and the Base Material Properties, and even has input for Lubricated/Wet Threads (K Factor). Can do both American and Metric Bolts:

    http://www.futek.com/boltcalc.aspx?mode=metric

    Factory Pipe typically recommends about 32 ft-lbs on the 3 Head Pipe bolts (10mm x 1.25 x 40mm). Not sure of Grade and Material type...

    How do the "Kalkalata" results compare to the 32 ft-lbs spec'd by Factory Pipe?

  4. #4
    Resident Guru JC-SuperJet's Avatar
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    Re: Replacement of OEM Bolts with Stainless Steel Bolts

    So I assumed stainless steel bolt thread engagement (swallow as per Oil Patch) to be 13mm deep (Bolt Length 40mm minus the Cast Thickness 27mm); results are:

    Metric
    Warning! It is highly recommended that a bolt's engagement length be at least 1.5 times its diameter. (this is to avoid Shear Failure)
    Application Data
    Major Bolt Diameter: 10.00 mm
    Bolt Pitch: 1.25
    Bolt Proof Strength: 517 MPa
    Recepticle Length: 13 mm
    Recepticle Strength: 276 MPa
    Applied Tensile Load: 0 kg
    k Factor: 0.18 (Lubricated)

    Recommended Torque
    35.23 N-m
    (3.594 kg-m)
    (25.98 ft-lb)
    Resultant Tension:1995.4 kg

    Maximum Torque
    46.97 N-m
    (4.792 kg-m)
    (34.64 ft-lb)
    Resultant Tension:2660.6 kg

    So 26 ft-lbs versus Factory Pipe Head Pipe Bolt 32 ft-lbs... Is this realistic?
    Last edited by JC-SuperJet; 10-17-2018 at 02:23 PM.

  5. #5
    PWCToday.com Is My Home Away From Home mcn6's Avatar
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    Re: Replacement of OEM Bolts with Stainless Steel Bolts

    I use non permanent (usually blue) Loctite and I Time-Sert them only when the aluminum manifold threads become worn. I have never used a Helicoil for that fastener so I can't really comment on them.

    I have always used the torque value as listed in the Kawi X-2 service manual (36 ft-lb). I don't remember why I started using that torque value, but that's what I have always used with the FPP exhausts.



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  6. #6
    PWCToday.com Is My Home Away From Home Grumpy Old Guy's Avatar
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    Re: Replacement of OEM Bolts with Stainless Steel Bolts

    X 2 on Timesert. 100 X better than helicoil.

    Torque smork...tighten that F'r down.

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