I just noticed last night while giving my Fat Bob a once over that the exhaust bracket lower mounting stud is broken off. I bought the bike last September and changed to the D&D Fat Cat 2-1 in January of this year. Installation was done by me per D&D's instructions and the Harley service manual for torque specs. I haven't had a bit of trouble until now! I called the dealer and spoke to the service manager to see if they would cover it under warranty. NOT. He said that if they had installed the exhaust they would cover it but since I did the install they would not. I pointed out that the stud BROKE. The stud acts as one of the transmission side cover bolts so it is torqued at the factory when the tranny is assembled. The bracket then attaches to it with a self locking nut. The nut was torqued to spec. Grrrrr. Anyway, they won't be seeing my bike any time soon. It hasn't been back there for work since I bought it cause I don't believe in paying $330 for a glorified oil change (service) so I have done all my own work. ANYWHO, anyone else have this happen with the studs on the exhaust mount? I have no idea what it would cost to have the stud piece removed as it will have to be drilled out. I've got the other stud and bolt so what if I just let it ride and hope for the best? Potential leak from the tranny? Thoughts?

 

I recently noticed both studs broken on mine. I went to the dealer to get the new studs, and the service guy said they'd fix it under warranty. I have the stock headpipe with Rush slip-ons. Maybe it depends on the dealer; is there another one in your area you can call?

 

I've seen posts before about this. Definitely check with another dealer. Good luck.

 

i noticed recently one of mine was broken also. the upper left one in your picture. and the nut was missing off the lower. will try to fix when i swap the exhaust..

 

I have a 2009 FXDF. Exact same thing happened to me. The dealer said is was a known problem. They fixed it under warranty. Good luck.

 

I'll be calling Harley customer service tomorrow on this and see what they have to say. That stud shouldn't have broken like that.

 

I'd put the stock exhaust back on and take it in for warranty service.

 

Mine came out with the nut attached like it was a bolt - I've taken it on and off a few times since that and still works the same. EDM might be a better way to remove it - wont damage the case.

 

EDM? What is that? Exceptionally Delicate Method?

 

EDM - simple answer is spark erosion