Bandit exhaust removal.

[boredatwork]

hi

ive read a lot of the relevant threads here about exhaust studs and their prone-ness(?) to snapping etc.

however i have been told by the garage that to replace my exhaust will be 400+vat for the system, and at least £100 for the fitting but most probably more because "a stud is bound to snap and then its going to get expensive"

so i have decided to risk it.

my plan is a campaign of wd40 /gasflame? soaking of bolts prior to the day of destiny.

is there any advice or warnings i should heed?

am i being stupid, should i just pay for the work?

also has anyone used the banditmania send of repair service? any comments (via pm if prefered)


thanks in advance
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DAS/Test: Passed March 08!
Bikes: CG 125 and k4 750 gsx-r

[Bezzer]

The exhaust bolts can be a bitch to get off, but mine aren't I take them out every few months and copper grease them
Use Plusgas not WD40 much better stuff and have a go at them straight after it's been running so it's nice and hot, wear decent gloves though. If the standard hex key starts to round them off next step if to bang a torx bit in and try that. When you've rounded the inside hex then the ultimate removal method is to get a multipoint 1/4" drive 12mm socket and bang it over the bolt head, it's spot on size to dig into the outsides of the bolt then use a ratchet to undo, works in most cases.
You might get lucky and they come out easy depends when they were last taken off. The bolts are M8 25mm long if you're going to replace them.
Banditmania do a good job on the exhaust repair but it is expensive, mate took his to a local stainless welding firm and they did it for a tenner, they only have to weld a stub of 60mm stainless tube inside it.
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I used to be indecisive but now I'm not quite so sure.

[boredatwork]

plus gas! sorry i feel a right twit for gasflame!...

i've already had a local guy try fixing it and its gone, right on the bleeding join between the two bits.

i got the impression the banditmania was more than just a weld job?

im half tempted if i manage to get it off to replace the whole thing for new but its soo expensive!

thanks for the advice, i will be ordering some plus gas now - i wasted a lot of time this morning googling trying to find it!
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DAS/Test: Passed March 08!
Bikes: CG 125 and k4 750 gsx-r

[SonicTheHedge...]

It's (IMO) worthwhile getting a new stainless system, as you'll just be able to ignore it from then on, or, failing that, see if you can find replacement downpipe/collector/linkpipe assemblies that let you keep your silencer, as that might be cheaper.

As long as you use plenty of penetrating oil over plenty of time (mine took 3 days of torture) you should be able to get 'em out - it's the right combination of brute force and gentleness.
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