What a Stud

[ShinySideUp]

So there I am, crouched down doing the valve adjust ritual mumbo jumbo when I notice the rear-most bottom stud holding the left cylinder head on the block protrudes way beyond its nut.

All the other 7 studs stick out about 1-2 threads, but this outlaw is sticking out about 6 or 8 threads, over 1/2".

I think to self: "Ach sh*iss! This is not right. Even Hardly Davidson wouldn't do something like that. That stud must have been pulled out of the block by some ham-fisted mechanic."

So, while the bike is under warranty, I have the dealer check it out. Upon hearing the description over the phone, the service manager agrees: "That's not right; bring it in."

Upon hearing the issue from the SM, the head mechanic says, "That's normal."

REALLY," I ask and the skepticism was probably dripping off my face.

"There's a service bulletin on it, if you don't believe me," he says.

Yep there is: Bulletin No. 11 002 04 (050) Date: May 2004 is for the 1200 GS engine but applies to us. It says right there:

Eight equal length studs are used to secure the cylinder heads to the engine case...

On the left cylinder head, the bottom bolt on the inlet side will, when properly assembled, show more threads beyond the locking nut than the other seven.

Correctly assembled and torqued, there will be 16.5 mm (0.649 inch) of threads past the locking nut.

And then in BOLD PRINT:

Important Note: Under no circumstances should any attempt be made to screw the threaded bolt deeper into the engine block, as this would cause damage to the block.

Nice pictures are included with the offending stud circled.

Those Germans weird me out sometimes. Must be the same designer that came up with different thicknesses for the rear brake pads!

All's well that ends well. I guess it's more economical to issue a service bulletin than to cut one of the studs.