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#140903 - 03/06/18 03:52 PM Re: Removal of Header Pipe [Re: garywi]
peejman Offline
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Registered: 06/03/13
Posts: 2981
Loc: East TN USA
Strength of the bolts really isn't the issue, corrosion is. Stainless bolts/studs might help, but regular grade 8 with some anti-seize should also be fine. It's not something you're going to be removing routinely.
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This shall pass, be still and know.
2006 XT225, UNI filter, ProTaper bars, MSR handguards, SS front brake line, Shinko 241's.

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#140904 - 03/06/18 04:13 PM Re: Removal of Header Pipe [Re: garywi]
thinman Offline
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Registered: 12/19/16
Posts: 46
Loc: Toronto, Ontario
Bolt stregth is important to prevent twisting the head off the bolt, especially in this application where heat and corrosion are an issue.
In my air cooled vw engine I use steel studs with soft copper nuts that are made specifically to solve this problem.
As an aside, there is no grade 8 in metric. 8.8 is the minimum you should use.

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#140911 - 03/07/18 01:07 AM Re: Removal of Header Pipe [Re: garywi]
garywi Offline
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Registered: 02/12/11
Posts: 516
Loc: Somewhere, Arizona
Thanks guys. I think I will use penetrating oil for a few days, then go on a long ride to heat everything up. Then hold some ice cubes to the head of the bolts. Then, rap the bolts once with the impact driver. Then take a socket an apply very light pressure and see if they brake free. :-)
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2002 XT225 PC. Restoring to like new. Rox risers, jetting, 16t, X-ring, Skene LEDs, ceramic header, 3-horn mod, garage door mod.

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#140912 - 03/07/18 01:32 PM Re: Removal of Header Pipe [Re: garywi]
peejman Offline
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Registered: 06/03/13
Posts: 2981
Loc: East TN USA
Originally Posted By: garywi
Thanks guys. I think I will use penetrating oil for a few days, then go on a long ride to heat everything up. Then hold some ice cubes to the head of the bolts. Then, rap the bolts once with the impact driver. Then take a socket an apply very light pressure and see if they brake free. :-)


Using a torch on the head next to the bolts will be much more effective than riding it. Riding it will heat the header pipe faster than the head (you want the opposite) and it will also burn out any penetrating oil you put in there, which could turn to coke and make the problem worse, depending on how hot it gets.

You've got to keep turning pressure on the impact driver while you're hitting it. You'll be a lot less likely to burn yourself if the header isn't hot.
_________________________
This shall pass, be still and know.
2006 XT225, UNI filter, ProTaper bars, MSR handguards, SS front brake line, Shinko 241's.

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#140915 - 03/07/18 02:53 PM Re: Removal of Header Pipe [Re: garywi]
Muniac Offline


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Registered: 01/16/04
Posts: 5530
Loc: Montrose, CO
I'd work with a cold attempt first using a penetrating oil. Light impact with a rawhide mallet is also a good idea. Add the oil, wait, hit with mallet, etc. Couldn't hurt to repeat the cycle at intervals for a couple of days. You might get lucky.

Aluminum has a high coefficient of thermal expansion. If you can heat the surrounding metal that will help. You can keep temps below what burns off any oil added.

As for impact, another tool I use is a Starrett automatic prick punch. This imparts a quick mechanical pulse into a small area. You can use this right in the socket head. Seized bolt removal is somewhat of a black art requiring some dickering around. I like to work from least aggressive to more aggressive.

Stainless steel screws in aluminum female threads are notorious for galling problems. I'd be careful with that combination. Not sure any anti seize compounds can withstand high temps.

If you break it off and/or destroy the threads a heli-coil SS insert repair is your next challenge. I can tell you (from experience) this is a delicate and tricky procedure. But it will restore the threads to better than OEM. Good luck.
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#140919 - 03/08/18 01:20 AM Re: Removal of Header Pipe [Re: garywi]
garywi Offline
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Registered: 02/12/11
Posts: 516
Loc: Somewhere, Arizona
Thanks Guys!
_________________________
2002 XT225 PC. Restoring to like new. Rox risers, jetting, 16t, X-ring, Skene LEDs, ceramic header, 3-horn mod, garage door mod.

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#140923 - 03/08/18 08:48 AM Re: Removal of Header Pipe [Re: garywi]
Newb Rider Offline
Junior Member

Registered: 11/23/17
Posts: 64
Loc: ACT Aus
I just undid mine. With an Allen key. Got lucky I guess?

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#140925 - 03/08/18 12:25 PM Re: Removal of Header Pipe [Re: Newb Rider]
garywi Offline
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Registered: 02/12/11
Posts: 516
Loc: Somewhere, Arizona
Just curious, why were you taking it off...
_________________________
2002 XT225 PC. Restoring to like new. Rox risers, jetting, 16t, X-ring, Skene LEDs, ceramic header, 3-horn mod, garage door mod.

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#140935 - 03/09/18 10:02 AM Re: Removal of Header Pipe [Re: garywi]
Newb Rider Offline
Junior Member

Registered: 11/23/17
Posts: 64
Loc: ACT Aus
Took the bike to bits, had various niggles when I bought it. Just tinkering really.

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