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Cylinder studs pulled out of block

Thanks bodeen I really needed this info. I don't really know why. It blew the head gasket while on a road trip but it made it home. I originally checked the stud tightness but didn't actually try the torque load because it felt really tight and didn't rotate any so I put the new gaskets in and made it to about 35ft lb and started to rotate and not tighten so I am at a loss at this point. Thanks again I will examine further the issue and it there are no cracks we'll get after the inserts.
:D
 
I would replace the studs also, they may have stretched. Be sure to lube the threads prior to putting on head bolts. Just don't get any oil on the ends, that can change your torque value.
tourbox
 
Yep, Time-sert. Went through this with my 95 Ultra last year. Head gasket blew. Threads in the crankcase were stripped. Take your time and it's an easy fix. The time sert insert is much stronger than heli-coil. It's a solid piece. Comes with good instructions. I think the kit is around 100 dollars.
 
The other really critical step is to be sure that you are drilling at the proper angle. Maybe take the time to set up a jig to keep you drilling on plane would be time well spent IMO.
 
INSTRUCTIONS
-J01679
REV. 7-25-2001
HIGH PERFORMANCE CYLINDER STUD KIT
General
This kit is designed for installation on 1984 and later models
equipped with Evolution engines. This kit is required on engines
with compression ratios of 10:1 and higher. For engines with higher
compression ratios, Screamin’ Eagle gasket kit part number 17046-
98 is also recommended.
Kit Contents
Quantity
Description
Part Number
8
Cylinder Studs 16502-01
NOTE
A Service Manual for your vehicle is available at your Harley-
Davidson Dealer.
The rider’s safety depends on the correct installation of this
kit. Follow the procedures listed in this Instruction Sheet and
in the appropriate Service Manual. If the procedures are not
within your capabilities, or if you do not have the correct tools,
have your Harley-Davidson dealer perform the installation.
Failure to correctly install this kit may result in death or
serious injury.
Installation
To protect against shock and accidental start-up of vehicle,
disconnect the battery cables, negative cable first, before pro-
ceeding. Inadequate safety precautions could result in death
or serious injury.
Always disconnect the negative battery cable first. If the posi-
tive battery cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery explo-
sion which could result in death or serious injury.
1. Disconnect the battery, negative cable first.
2.
Remove top end heads and cylinders according to Service
Manual instructions.
Cylinder studs that are bent, scratched or broken must be
replaced. Broken and bent studs distort clamp load, while
scratches produce stress risers that may eventually lead to
broken studs. Distorted clamp load causes head gasket
leakage that may result in engine damage.
Do not use a ratchet or breaker bar to install cylinder studs
because they will bend the studs.
3. Remove existing cylinder studs according to Service Manual
instructions.
4. Install new studs, Loctite end first.
• Place a 0.313 inch DIAMETER BALL, HD Part Number 8860
(or from the XL clutch release mechanism) into the head bolt
recess. Thread the stud into the head bolt until the stud
bottoms on the ball.
NOTE
Pack clean shop towels into the crankcase openings to prevent the
ball from falling into the flywheel compartment when removing the
head bolt.
• Clean the threads in the crankcase.
•
Studs have a Loctite patch on the crankcase end
threads.Install the studs in the crankcase with the Loctite
patch side down.
• Use a T-handle to install the studs. Install studs until the free
length is 5.71 ± .05 inches.
See Service Manual for more detailed information.
5. Check all studs for proper height.
6.
Reinstall the top end heads and cylinders according to the
Service Manual Instructions.
Always connect the positive battery cable first. If the positive
cable should contact ground with the negative cable installed,
the resulting sparks may cause a battery explosion which
could result in death or serious injury.
7. Reconnect the battery, positive cable first.
8. Do not start engine for a full 24 hours to allow Loctite to cure.
Allow Loctite to cure for 24 hours before starting engine, or
engine damage may occur.
CAUTION
1
WARNING
CAUTION
CAUTION
1
WARNING
1
WARNING
1
WARNING
®
Kit Number 16503-01
Loctite patch
Install this end up
Figure 1. Cylinder Stud
i03377
Did your studs strip or just loosen up and wind out a bit? Common problem on Evo engines
 
I used a small machinist square to align the drill bit with the hole. You're only taking out a very small amount of material.
 
Thanks guys, I really appreciate the help and guidance. Parts are ordered and should be getting back on the road soon.:D
 
Okay one Time-Sert in three to go. Talk about stressful activities. The drill bit is so sharp and cuts so fast it's kind of hard to gauge the speed needed to cut smoothly but I took my time and the Time-Sert is in good and tight. So will try the other three tomorrow. Thanks for all the advice and help .:):)
 
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