stuck headers

[KingB3N]

ok i got my new exhaust this week, so i take my old one off, all goes fine except on the middle 2 pipes the last inch or so snapped off and is now stuck in the engine. they look like they have been rusted in.

has anyone else had this problem before, and how do i get them out!

cheers

ben

[Kickstart]

Hi

Is it the actual header or the bolts holding them to the head?

If it is the header then it should come out with a bit of wriggling and some WD40. For the bolts you will probably have to drill them out. Personally a job I hate as it is far too easy to wreck the head. You could try using an easy out, but be aware that these are hardened steel and should they break then the results are VERY difficult to remove.

All the best

Keith
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[KingB3N]

no all the bolts are out, its just when i went to take the exhaust off the middle 2 bits snapped of in the engine, i've soaked them in wd40 and will try again later.

[KingB3N]

ok just had a better look! they appear to be wielded in to the engine!!!!!!!!!
So now im gonna have to call out a mobile mechanic and see if he can get them out

[Kickstart]

Hi

This is on a CBR250? They should not be welded to the engine (engine is alloy, exhaust is steel).

I think M1ke has a workshop manual for the CBR250 so he might be able to help.

All the best

Keith
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[KingB3N]

no no you don't understand

ok i went to take my old exhaust off....the left and right headers came out of the engine fine....however the middle 2 were that stuck in the pipe just snapped off leave me with 2 inch long headers stuck in my engine. On closer look they look like they have wielded to the engine, almost like some idiot who owned it before me has put the wrong type of gasket in and its melted under the heat!
anyways i have banged at it now for a couples of hours and they just ain't budging.
Is it worth calling out a mobile mechanic, or is there a specialist i can call to see what they can do?

thanks

[Scooby]

You aren't making it really clear whats happened, so I can understand why Keith is having trouble translating it, because so am I. Personally, if you don't know 100% what you're doing, take it to an engineering company and they can drill the bolts out (if you've snapped them off) for £300 tops.
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A big enough hammer fixes anything!

[Kickstart]

Hi

Right. Not sure how is best to get that out. You could try with a Dremel, being careful not to catch the engine. The other point is that if you can cut a groove up the remaining part of the exhaust then it can contract a small amount, hopefully breaking the seal so that it will come out.

With the right equipment there are probably other easier ways to get it out (freeze it would with liquid nitrogen for example), but not sure what could be done by a mobile mechanic.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Ninja]

5 minutes with a blowtorch each and several sharp taps with a small lump hammer should break their 'grip' on the head
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James
4 wheels transport the Body ... 2 wheels transport the SOUL