How to remove rusty header pipes?

astle · L Plate Warrior Joined: 13 Mar 2005 Karma :

Hi,
I have just bought a Bandit and need to fix a rotten exhaust (common problem so i have been told). Bandit Mania do a repair service but first i need to remove my header pipes. I managed to remove all the bolts but pipes 2 and 3 wont budge from the engine.
Anyone have any tips for removing them?

Cheers.

stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

Soak them in WD40 overnight then roast them with a blowlamp and wiggle away (with heat-proof gloves on).
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sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Rubber mallet.

White Noise · Mr Dudwee Joined: 17 Dec 2004 Karma :

unlucky man, i have had the same problem, i had to replace the downpipes on my divvy, simple i thought only 8 nuts to undo. turns out they have rusted to crap and the hex thread inside the bolts heads where none exsistent! after much scratching of heads by me and davo we got our hands on some screw extractors, soaked the bolts in WD40 over night and used the extractors, and to be honest they are a god send!!!
managed to get them off and replaced the nuts with stainless steal ones, took the pipes of two day ago and they came off very easily!
Hope yours come off easier than mine, don't forget copper ease on the threads when you put them back on!
WN
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astle · L Plate Warrior Joined: 13 Mar 2005 Karma :

I have managed to get the 8 bolts off it is the pipes that wont budge, i am going to follow previous advice and give them an intensive few days of WD-40 then get a blow torch on them and hope for the best.
I did not expect them to stick once i have removed the bolts Sad

White Noise · Mr Dudwee Joined: 17 Dec 2004 Karma :

yeah wouldn't have expected that i think applying heat to them and a bit of percussive theopy with a rubber mallet
good luck
WN
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Buy my wife: 96' Yam XJ600s (Diversion)
Wing Commander White Noise - SE Clique
Riding Tip #86: See God, then back off a bit: Problem is i haven't seen god yet, just a close up of tarmac on revett straight

mchaggis · World Chat Champion Joined: 10 May 2004 Karma :

The judicious use of a length of wood to act as a lever with the engine block as the fulcrum might be handy. I wouldn't place bets on them not being damaged as a result, so try at your own risk; padding the wood with cloth/ something wound around it could help.
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astle · L Plate Warrior Joined: 13 Mar 2005 Karma :

3 days of WD-40, one blow torch and a lot of swearing and they are now off!
Thanks for everyones help.
The end of pipes 2 and 3 are quite badly corroded meaning I may have to buy some new pipes Sad

but at least they are off.