Sv1000 exhaust removal

[Niall_farley]

Whoever had the idea to put Allan head screws in the back of a hot exhaust on a motorbike want shooting in the face!

Three of four seized on each silencer.... How is best to remove these? I don't mind replacing them but been Allan bolts the key just wants to twist out or even round off just can't get the purchase I need!

Any ideas on how to remove?

Thanks in advance

[dirtydog]

Are they cap or button head bolts?

[Niall_farley]

Daft button head bolts! Couldn't have made it more awkward

[dirtydog]

What a stupid idea to use Allen bolts let alone button head ones!
I think if they're tight enough that they're going to round out you may have trouble with them shearing off you can get something on them.

I was going to suggest irwin bolt extractors if they were cap head.

You still be able to get the bolt extractors on a button head but the socket won't have much to bite into, I've used them on a tokico caliper that the Allen bolts were rounded out

[Bibio]

all the exhaust studs on pointys are allen head.

bit late now but if you are taking the exhaust off you loosen the two clamps, dont touch the rear exhaust header ones and fully remove the front header ones then remove the front downpipe and take the rest of the pipework off leaving the rear downpipe in place.

[Niall_farley]

Cheers bibio.... I just I need the rear silencers off ready for the mot next month (lost a baffle last mot when I went for a blast forgetting that I only finger tightened them for the test... DOH)

Access is a pain as well because of the hangers but I can soon remove them.

Bit idiotic using button Allen heads on a exhaust if you ask me..... Morons! Never mind tho ey!

If I drill the top off it's not going to leave me much bolt to grab with pliers either.... Hmmm might be easier to just give it to a garage and make it their problem

[maviczap]

Someone one here posted up removing stuck bolts using a similar method to this. Depends on your access

[Niall_farley]

Thanks maviczap I'll have a go with the punch this next week see what I can do

[Ratty]

These bolts are not bad quality and should have moved quite easily with a good quality long series key, especially if you give them a sharp hefty tap on the head first. Mine came out easily when I fitted after market cans at about 10K and came out easily again yesterday ( after 7 years ) when I removed most of the system to replace the rear collector gasket. You should be able to cut a slot in at least 3 each side to attack with a large driver. The inaccessible one on each with prove tricky and may need drilling. Use graphite grease on reassembly.

Alan

[Niall_farley]

Cheers Alan! I suspect with a name like yours you had something to do with the invention of these and are therefore a ambassador for Allen bolts across the globe.... Shifty....