How to remove exhaust headers? (Pointy)

[Stu]

Any tips please before I attempt this.
Saw Grinch do it on a Curvy, but will need to get the rear stub off as well. And I learned the valuable tip of ensuring all relevant bolts are undone before hitting it with a big hammer.
Anymore?
Cheers

is it just a standard system?if so it will be easy enough off but the micron system i have on my bike is a bit of a nightmare 2 get on and off my bike lolas from the front 2 the back is only 2 pieces and the orignal sv one is 3 so hence why its hardish.

Originally Posted by Stu

but will need to get the rear stub off as well.

You don't need to remove the subframe to take the exhaust off or are you taking the subframe off anyway?

It's quite easy, there is one clamp on the rear downpipe which requires a long reach allen key and one clamp under the engine on the front downpipe plus the two heared nuts on the front and three other bolts holding the rest on (silencer, below footpeg, and underneath engine near where both downpipes meet). Once all undone simply knock the front header forward and downwards with a rubber mallet and it should all come off.

[Rich]

I just removed my system recently for a good clean. Was easier than i thought, the rear clamp bolt was abit rusty so i gave it a good dose of wd40 and left it abit then bamb it undid first time. Make sure all the other bolts are undone, i suggest taking the front pipe and exhaust off first then give the rear piece a good twist to get it going and it should all being well slide out..

Rich

[Stu]

Originally Posted by Dangerous Dave

You don't need to remove the subframe to take the exhaust off or are you taking the subframe off anyway?
.

Who said anything about the subframe
I mean the rear header has a short stub at the engine which looks really recessed to be able to get at it.

Originally Posted by Stu

Who said anything about the subframe
I mean the rear header has a short stub at the engine which looks really recessed to be able to get at it.

Oop's, misread that! Get the system off first then you can access the two nuts that hold the stubbed bit on easier, you could remove the shock for easy access but it can be easily done with a universal joint on the socket extension bar!

[Stu]

Originally Posted by Dangerous Dave

Oop's, misread that! Get the system off first then you can access the two nuts that hold the stubbed bit on easier, you could remove the shock for easy access but it can be easily done with a universal joint on the socket extension bar!

OK, thanks. I hope Dirtydog has one of those

Otherwise, anymore last tips before I render my bike un useable?

[dirtydog]

Originally Posted by Stu

OK, thanks. I hope Dirtydog has one of those

I do have one of those

[Stu]

Well this didn't go well. Both bolts for the front pipe into the cylinder head snapped off. Both drilled ready for stud extractor, which broke off in the first bolt.
So I've found http://www.delentooling.co.uk/main.htm which has a spark eroder not too far from me, but they want the cylinder head off the bike to put in their machine.
So any easier option? such as helicoil? anything else?

Any offers of help?

Thanks.

[Red Herring]

I snapped the bolts off on my front cylinder as well, apparently they are really prone to it. I wasted hours trying to do it with the head still in situ, but in the end took it off. It comes off really easy and for the sake/price of a head gasket it's by far the best route. If you have broke a stud extractor off in one of the bolts you could be in trouble, unless you have managed to get it out it will be virtually impossible to drill the stud out. Did the bolts snap off immediately behind the bolt head leaving you with about 1/2" of stud sticking out or flush with the cylinder head? If the former you can try welding a nut over the top of the stud and getting it out that way, if not it's going to be a trip to a good engineering workshop, but it will be worth it, heads are expensive....