Well, I am new to the motorcycle scene but I'd like to believe that I know my way around a spanner.
I have thoroughly doused the 4 reaming exhaust nuts and the 8 exhaust studs in penetrating fluid, one of which has been snapped before I acquired it. I left them penetrating for a few hours and I have not been able to make them budge save for one a matter of millimetres. I'm trying not to shear the remaining studs but I fear that the reaction between the dissimilar metals has seized the clamps onto the studs.

So what's your best advice/ideas as to how to remove the exhaust?

Cheers for your wisdoms!

Just a head up I snapped 3 out of the 4 studs that go into the front cylinder head today and have spent all day getting them out.

Ive got 2 out and one remaining and its been a compleate nightmare. The head might still end up been scrap.


Id add heat if you have it and take it really easy. Mine where like butter though. Didn't matter what i did to them they would have gone.


One I managed to hammer a 5mm socket onto and the other was so rotten it wouldn't take it. ended up drilling it out and using a star bit.



Good luck sir

Run the engine up so its hot before trying to remove may help

ah the engine isn't complete so I can't run it up (no carbs). the problem you are having bodge is exactly what I want to avoid.

Try a blowtorch.

Are there any weak points on the head that I should avoid as I suspect I'm going to have to pry them off with a crowbar as well as the the torch.

Keep dousing with the penetrating fluid for as long as possible if clamps stuck on pipe or studs loads lube heat then gentle leverage should get fronts out step away from the crowbar please

just put as much WD40 on as possible got must the corroded nuts and studs out but did snap two of the front studs had to get them drilled out heat, stud extractor just weren't going to work with mine.

Kennon

Well after a ferocious evening of fighting very delicately i came away with a sort of success, all the headers are off and 6 of the studs are perfectly useable, one came out of the head damamged but the head threads are fine. Annoyingly one snapped (which isn't as bad as it could have been, i am greatful to the advice you guys gave) and even worse is the stud has snapped off leaving a slight recess into the threaded hole, maybe three or four mm.
So my question now is this, is my only solution to drill out and rethread/helicoil or has anyone managed the miracle of stud extraction from inside the head?

steed wrote:Well after a ferocious evening of fighting very delicately i came away with a sort of success, all the headers are off and 6 of the studs are perfectly useable, one came out of the head damamged but the head threads are fine. Annoyingly one snapped (which isn't as bad as it could have been, i am greatful to the advice you guys gave) and even worse is the stud has snapped off leaving a slight recess into the threaded hole, maybe three or four mm.
So my question now is this, is my only solution to drill out and rethread/helicoil or has anyone managed the miracle of stud extraction from inside the head?

Good screw extractors can work but dont overdo it, stud extractors are a pain in the arse to drill out as they are hard.

Have you heard of loctite freeze and release spray? It like the opposite of blow-torch, -70c or something you spray on to things to contract them to break the rust seal..

I tackled some pesky buggers by alternating between a very hot torch and freeze spray and as soon as it came loose i could undo it with my fingers.

best of luck!