Honda CG125 exhaust hole

[blueplatypus]

My Honda 2004 CG125 is my first bike, I've only been riding it for about 4 months, it's had a couple of problems but nothing I couldn't do myself with a bit of help.

Last week though while I was cleaning it (I don't do this as often as I should) I came across some flaking chrome where the exhaust manifold connects to the engine. I then pushed on it a bit and found it was totally burnt through!

I managed to order a new one online for 70 quid and got really excited about having a nice shiny chrome pipe to replace my dull and rusty one, not to mention the sound and performance improvements I'm anticipating.

I managed to get the old exhaust off today and found it was totally burnt, the flange which holds the pipe to the engine was welded to the pipe so the heat that was coming out must've been phenomenal.

Getting to my problem, there should be a gasket on the end sitting inside the engine where the pipe meets it, I have bought a new one but can't seem to get the old one out - maybe there isn't one there but I think I can feel it fused inside. Anyone have any ideas for what I can do to get it out?

Pictures to follow soon

[N cee thirty]

flathead screwdriver to pick it out
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'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

[blueplatypus]

[BigGeeking]

there should be a copper crush washer inside the port sometimes they have coke on them and look black get a soft nylon abrasive pad and give it a rub or very softly scrape a flat head on it and you will see the copper.
just pull it out but be carefull as the block is only alloy

think they are about £1.70 from wemoto
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Bendy "Flip front. I can filter down the M4 while shoving a Twix in my face."
honda CG 125 2001 SOLD-- current Bandit 400--SOLD. current SV650s 2000
MOD 1 ON 20/7/2011**passed** MOD 2 ON 17/10/2011***passed***,,

[Rogerborg]

Yup, it can be hard to see where the gasket is. They get pressed in so hard that - by design - they end up looking and feeling like an integral part of the manifold. Believe that it's there, and get digging with a thin screwdriver and you'll soon find the edge and work it loose though.
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Biking is 1/20th as dangerous as horse riding.
GONE: HN125-8, LF-250B, GPz 305, GPZ 500S, Burgman 400 // RIDING: F650GS (800 twin), Royal Enfield Bullet Electra 500 AVL, Ninja 250R because racebike