www.zxrworld.co.uk

Hey everyone,

Tried to get the exhaust off to change the gaskets/give it a good clean but the flanges are bent and will not slide off of the bolts attached to the head.
Tried bending them back to no avail.
Any advice/ suggestions greatly appreciated!!

Many thanks

Have you tried prising them off?

Yeah but i don't want to risk damaging the parts - it could make a mess of the thread on the screws - unless the screws can be removed...?

Thanks

Tried some WD40?

If you cant get them off then you might not have much choice but to bugger the threads. They can be changed if need be, they do screw out, but you might be doing something wrong if they are being this much of a pain to get off. Your other choice might be to put two nuts on and tighten them against each other and screw the stud out but im not sure how much additional thread there is for you to do that.

Would it be too much to expect that you have slackened/removed the other fixing for the exhaust to allow the whole thing to move this would aid removal considerably

Not at all - The whole system moves but forward motion is restricted due to the flanges getting stuck in the threads of the screws.
There is plenty of thread for me to get two bolts on so will give that a go at the weekend.

Thanks for the advice guys - will let you know my progress.

I would be trying to wriggle the exhaust off and also trying to prise the flanges off.

before trying to remove the studs.................you could open a real can of worms if one of them shears off leaving you with a much much bigger job to do

cargo wrote:I would be trying to wriggle the exhaust off and also trying to prise the flanges off.

before trying to remove the studs.................you could open a real can of worms if one of them shears off leaving you with a much much bigger job to do

That is a good point actually.

drilling

tapping

rebuilding with weld

broken drill bits

prob engine out

big can
huge worms

Crikey! It's a good job I decided not to give it a go!
I will have to tackle it in the future - It works fine, just doesn't look great thats all - Tightened them back up for the time being.

Thanks for your help though gents

Hey,

Thanks for the double bolt suggestion - Managed to get them all out and the exhaust off.
Turns out the bolts are bent - All of them!
Just ordered a new set and will be back on the road in a couple of weeks. I have spent a lot of time cleaning her up and fixing/ respraying fairings etc.
Think it's worth a post in the re-build section?

Many thanks

Just I case anyone is interested, I managed to snap of one of the bolts when removing my exhaust headers, I tried wd-40, heat, mole grips, and it would not budge, I then had a brainwave. if you have a dremel, or for certain bolts you can use a hacksaw if space permits. Cut a groove along the end of the stud so it looks like a circle with a line through it, make sure its relatively deep, you can then use a screwdriver to try and turn it or a screwdriver bit on a ratchet via a coupler. Just thought I would share this as it has now saved me many hours by not having to drill, tap etc.

them bolts are always bent from the heat