Suzuki GS 125 Exhaust Bolts

[nitrosurf]

Hi all,

Bought a nice NOS exhaust for the other half's bike, started unbolting the old one and found that one bolt came away easily, the other is veryveryveryvery stuck. They're rubbish allen head bolts (why do manufacturers do that...) and the inside has rounded. I'm gently trying to remove it (hopefully I won't need heat as I don't have a torch), but that's not the issue. I cannot find replacement bolts online anywhere; does anyone know where I can order some? I'll take the originals to a merchant and have them sized for replacements if needs be, but thought it would be nice to just order a pair of 'genuine' bolts...

Cheers in advance!

[Snod Blatter]

One of the threads in the head of mine was very rough and allowed the bolt to rattle around slightly, so fearing the bolt stripping its way out I just replaced them with a couple of lengths of allthread, made sure they were secure with some red Loctite and then just used normal nuts to do the clamping. Worked a treat, and they didn't work loose like the original setup.

Just an idea.
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1994 CB250, 1984 CBX250RS-E, 1989 K100RS, 1995 TRX850, 2016 Z250SL

[Bezzer]

Suzuki usually use M8 exhaust bolts 25 or 30mm long just measure the one you've removed. Don't bother using OE ones as they are just a standard bolt at stupid dealer prices, get stainless aftermarket ones and use an anti seize on them then you won't have rust to deal with next time they come out.
If they are an M8 allen head you will find a 12mm multipont socket will hammer over the head and let you remove it 9 times out of 10 with a ratchet if the inner hex has rounded off.

[nitrosurf]

Thanks for the tips!

Back in the garage to try again in the morning so fingers crossed! Hopefully they'll come out nicely and are an easy size to replace.

[Suntan Sid]

You could try hammering a star bit into the Allen bolt head, I've got a few bolts out that way!
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"Everybody needs money, that's why they call it money!"

[sickpup]

[Bezzer]

[quote="sickpup"]
Don't do this. The many heat cycles an exhaust goes could easily cause the bolts to snap at which point stainless can be a bit of a nightmare to drill.[/quote]

The commonly available A2 stainless bolts are less prone to heat or work hardening and with a decent HSS drillbit are no harder to drill than a steel one.They remove rust from the seizing equation just leaving galvanic reaction which can be largely avoided using anti seize compound.

Granted if you use A4 ones which are advertised as super shiney and more corrosive resistant you'll have problems as they instantly heat harden and will blunt a hacksaw blade in a couple of strokes and blunt a normal drillbit no problem.

[Islander]