Exhaust header(s) leaking - Fixed.

[Beehive Bedlam]

FZS 600 2001.

Problem with header number 3 (I think) other three are tight sounds crackly around that area I think all four headers would benefit from new gaskets and studs/nuts because they are rusted to buggery I have tried nipping up the collar of the offending header but there is still movement.

I am not looking forward to removing the studs/nuts but I am the only man for the job I believe a garage will dive in head first and snap them I have been told this is a strong possibility. I am going to blast them every day with plusgas a week before removal in the hope they do not snap.

I imagine this will take me an afternoon all going well but in the mean time I still need to ride my question is other than it sounding like a bag of bolts and running rough is it going to cause any further damage?

I have a big mallet 10mm socket and spanner to get the nuts off/studs out and I am going to order plusgas/gaskets/studs anything else?

[Pete.]

[Rogerborg]

Good job on the prep.

You'll want to replace the nuts with brass ones.

I ended up cutting one of the nuts off of my Lifan, literally sliced through it with a hacksaw towards the collar, just missing the threads of the stud, to release its grip (other nut splitting / cutting tools are available). I'm not recommending it, just noting it.
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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

[wr6133]

Just weld it all to the sprocket, while your Arabian princess gazes in awe.

[Beehive Bedlam]

[andyscooter]

if you snap them its then your problem to sort it out

if they do it its then not your problem
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[delsol]

[RhynoCZ]

One thing before you try to take the exhaust off, spray every nut and bolt with WD40, and let it sit for awhile, that'll help to take them off. You don't want to break anything, do you?

Sometimes, even though you've got the same tools as the ''professionals'' you lack the basic knowledge and do unnecessary mistakes, that cost you time and money. And that is, what's the BCF for, to get the knowledge.

EDIT: Use butter instead.
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'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[Matt B]

I don't blame you for trying this yourself. It's not like the local bike shop has a magic way of removing exhaust nuts.

Keep on with the PlusGas, especially overnight or while the bike is sat for a long time.

Make sure you use a good quality 6 sided socket, not a cheapo 12 sided one. This will reduce the risk of rounding the nut off. Give the socket and extension bar a few brisk taps with a hammer before trying to turn it. You could also apply some well directed heat to the nut with a small blowtorch.
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stinkwheel: He had an animated .gif of a cat performing fellatio. It's not socially acceptable. It can have real life adverse effects on other people.

[Rogerborg]

[Raffles]

You did recently say that you wanted a louder exhaust. You've got one now.
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A good loser will always be a loser.

[nowhere.elysium]

[RhynoCZ]

I've been using WD40 (if I had no penetrating oil) to loosen up rusty stuff, since I could hold a spanner. I've never snapped a bolt/nut.
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'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[wots]

Took the ER-6 into a garage, as the notoriously crap headers needed replacing. Took one look and said, that they would most likely snap and didn't want the hassle.

After a week of plusgas, took an impact gun to it, and they all came off no bother. Bolts looked like cheese but they came off intact. Brand new studs in and all good.

It worked for me, but that doesn't mean it's the right way, I think Pete may disagree?
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Currently: Yamaha DT 125 LC2,Repsol Fireblade, and Bumblebee MSX 125

[weasley]

I did my headers a couple of weeks ago. Basically the same engine and everyone know the nuts seize, the studs snap and the downpipes corrode to dust. Except mine, where the nuts ran off without issues, all studs stayed intact and the downpipes I took off were still sound. I did use new OEM nuts and some copper grease, but could've used the old ones.
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Yamaha XJ600 | Yamaha YZF600R Thundercat | KTM 990 SMT | BMW F900XR TE

[yen_powell]

On my Varadero the gasket on the rear header where it joined the rest of the exhaust system used to disintegrate every 8-12000 miles.

The proper way to get to it is to dismantle the whole system. I wasn't gonna do that. I could remove the header in about 10 minutes without disturbing the rest of the bike. Putting it back was harder, access is extremely limited. The problem being threadling the pipe back through the maze, it was like the Krypton Factor.

To undo the header bolts I couldn't get closer than down by the rear wheel, many extensions were used to do this. I would say a short prayer before twisting. Oddly despite doing this about 6 times over 85,000 miles, I managed not to break anything. This was the main reason I switched to an inline 4 cylinder bike where I can see all the exhaust joints.

On the Varadero forums the search goes on for an indestructable exhaust gasket
https://i19.photobucket.com/albums/b165/yen_powell/P1100527.jpg

https://i19.photobucket.com/albums/b165/yen_powell/P1100530.jpg
https://i19.photobucket.com/albums/b165/yen_powell/varadero%20header%202/P1090254.jpg
https://i19.photobucket.com/albums/b165/yen_powell/varadero%20tech/P1090247.jpg
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[delsol]

BodyGuard has a length of scaffold tube he 'purchased' recently.

Jobs a good un.

[Fisty]

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Fatter and faster than Fret

[Pete.]

[Pigeon]

Might be of use

I a Dremel to take off what remained of nuts (....and a bit of the crank case and exhaust header ), plusgas, blowtorch, socket stud extractor to crack them, then molegrips to finish.
Got lucky.

[delsol]

[RhynoCZ]

Seems to me OP's gonna have to take the head off, for this one. Good luck with that.
____________________
'87 Honda XBR 500, '96 Kawasaki ZX7R P1, '90 Honda CB-1, '88 Kawasaki GPz550, MZ 150 ETZ
'95 Mercedes-Benz w202 C200 CGI, '98 Mercedes-Benz w210 E200 Kompressor

[Beehive Bedlam]

Interesting replies I am not put off by doing the job myself I intend on riding a bike until I can no longer hold one up so whatever tools I have to buy along the way will eventually pay for themselves.

[wots]

[kramdra]

One bit of advice I rarely see mentioned..

Run the engine first. Let it get very hot, with fan on before you start. It will be a bitch to work on, wear gloves to avoid burns..

You want the aluminum threads expanded. A torch will only locally heat the studs, that wont help.

Any pics for our entertainment?


If you snap them, its quite expensive. My bolts were soft and brittle, snapped 7. Honda bolts also reduce M8 to M7, making them exceptionally easy to snap off

It cost about £900 AND three months to get repaired.. but Ive done 25k miles since