Suzi GS550L stuck exhaust headers

[TerminalMan]

I've got myself a (seriously long term) fixer-upper here: a 1981 US import "barn find" GS550L, and I'm beginning to discover what I'm letting myself in for... Practically all the bits available for this item are still in the States, for starters.

Anyway, so far I've stripped most of the items off the frame, removed the rear wheel etc, etc. - and now I'm down to removing the exhausts before I attempt to pull the engine out and strip it down (yes, it's seized, like most of the rest of the moving parts). However, the exhaust header pipes won't come out of the cylinder head - I've tried penetrating oil, rubber mallet, planks of wood to lever them off, but they will not shift.

A mate suggested that I cut them off, but I politely informed him that I would then have to replace a perfectly decent exhaust system to the tune of about £300. No thanks. And I can't even break it all for spares, unless someone wants a seized engine / exhaust system bundle....

Any suggestions? I haven't tried heat yet, but that's my next effort.

Cheers,
Alan

[sickpup]

Put it on Ebay as a genuine bard find maybe?

[TerminalMan]

You might have a point! I'm stuck here...

[stinkwheel]

So the bolts are stuck in and you can't undo them or you've got the bolts out and the collars off and the headers are stuck in the head?

In either case, heat is probably the answer. Lots of heat, with a blowlamp so it's sizzling hot. There is a slight risk of melting the alloy but I doubt you could blast enough heat into an air cooled cylinder head with a normal blowlamp to do that. The aluminium alloy of the head will expand more than the steel of the bolts and exhaust when heated up.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Bhud]

Serious heat - MAP blowtorch.
Another way: cut the nuts off the ends of the exhaust retaining nuts/bolts. That way, you'll be able to slip off your intact exhaust system, and will be able to remove the engine. You will have to find a way to remove the remains of the rusty fasteners from your engine later.

EDIT: never mind that as it looks like you've already got the nuts out. Heat plus gentle tapping on the exhaust from behind, and you'll probably get lucky.

Oh, and check there are no rusted remains of half-moon collets still wedged up in there which are stopping you getting the exhaust out.

[TerminalMan]

Many thanks for that - yes, I've managed to get the bolts out and only sheared a couple of them (!). I've been suspecting that the collets got a little too comfortable in there and don't want to leave. Cue eviction by blowtorch!

I'll let you know if I manage to get anywhere with it.

[TerminalMan]

A *lot* of heat and rubber mallet work got the offending items off - I needed a drink after that!

Now to get the seized lump out, stripped and - hopefully - resurrected.

Thanks guys!