Header clamps seized - replacing exhaust

Ilyin · Renault 5 Driver Joined: 14 Apr 2013 Karma :

Hi all,

I'm trying too replace both pipes on a GSX600F 1997, there's 4 downpipes, but the bolts that hold the header clamps aren't budging. They're so tight that the allen keys are bending as I'm trying to turn them.

I've removed all of the plastic, and the fuel tank, and was thinking of putting a hot air gun on them to see if it helps.

I just though I'd check with you guys first in case it's a bad idea, or they're's a better method.

Thanks.

SQL · World Chat Champion Joined: 08 Aug 2012 Karma :

heat or impact driver

Itchy · Super Spammer Joined: 07 Apr 2005 Karma :

You mean the nuts on the studs?

If the studs are in good condition, then simply cut the nuts off with a dremel tool.

Because undoing them applies lots of force to them, which can mean snapped studs, snapped studs means PITA trying to get them out or drilling them out.
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Vincent · Banned Joined: 16 Oct 2006 Karma :

I'd soak with PlusGas for 48 hours then try a decent allen key with an extension bar. Or....use a socket with allen tip.
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Ilyin · Renault 5 Driver Joined: 14 Apr 2013 Karma :

Ilyin · Renault 5 Driver Joined: 14 Apr 2013 Karma :

Vincent · Banned Joined: 16 Oct 2006 Karma :

Bezzer · World Chat Champion Joined: 14 Apr 2005 Karma :

They're the same as Bandit ones, the time honoured method on them when they are rounding off or just too tight is plenty of Plus Gas some localised heat then bang a 12mm multipoint socket over the bolt head which fits the M8 allen head very snugly. The socket edges dig into the bolt head, the banging helps to loosen as well then use a socket ratchet to unscrew them. Take your time if they move then tighten again just work it back and forth.
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Ilyin · Renault 5 Driver Joined: 14 Apr 2013 Karma :

davebike · World Chat Champion Joined: 15 Nov 2013 Karma :

There M8 allen bolts (that is a 6mm allen key)

LOTS penetrating oil + heat repeat and repeat again

DON'T brake them
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Islander · World Chat Champion Joined: 05 Aug 2012 Karma :

Another thing worth a try is a freeze spray applied to the bolt head. I've had some success with Loctite Freeze n' Release - it's how I got the final header undone on the Hornet. Thumbs Up

Bezzer · World Chat Champion Joined: 14 Apr 2005 Karma :

Ilyin · Renault 5 Driver Joined: 14 Apr 2013 Karma :

Thanks so much all.

PlusGas and impact driver was enough for seven of the allen-bolts, the 12mm multipoint was needed for the last one.

Thanks again, I really appreciate it.