What was Suzuki thinking?

[str33tb1k3r]

What manufacture thinks its a good idea to put hex bolts on a exhaust manifold that is subject to high heat and water?

I managed to break free all but 2 bolts on my exhaust. They are rusted and rounded off. Any suggestions on breaking them free?

High heat + water + 21 y/o bike = ****ed off owner

[05RedKat600]

I thought Kats came with Allen head bolts? Now I gotta go check.

[phantasm]

Shouldn't be hex bolts. Should have been allen head. I've had luck on cars running the engine to heat up the block and using vice grips to get th bolts out. When you do get the be sure to apply plenty of anti sieze on the reinstall.

[Snapp600]

When vice grips cant turn em about, drill them things out!

[05RedKat600]

AHA! I was right. So PO replaced with hex heads.....nice. Gotta love silly people like that.

[steves]

They should be socket cap allens, and you should consider putting some anti-seize on them when you put them back together.

[05RedKat600]

They should be socket cap allens, and you should consider putting some anti-seize on them when you put them back together.

OP should also seriously consider procuring some stainless hardware to use along with anti-sieze...they will be even easier to take out next time.

[str33tb1k3r]

I meant allen head, sorry guys! haha

Would it be easier to drill them out and have a machine shop re-tap them?

I think I will cut the heads off to remove the header and try a stud remover, what do you all think?

[05RedKat600]

No. Cut a slot in them with a dremel tool or Hacksaw if you can. Try a large flatblade screwdriver first. Soak the hell out of them with PB Blaster, and try and do it when the engine is warm.

[scottynoface]

They were thinking who's going to replace the header on a touring bike.

[chrisx2]

Another approach if you are able or get someone to do is weld another fastener on to the existing bolt/allen heads and use that to remove them....but definately heating them before. Good luck.

[str33tb1k3r]

I soaked the hell out of them for 3 days prior to attempting to remove them. I had the engine warm when I first attempted to get them off. I will try one last time with the flathead and then who knows.

Thanks for the help guys. I will prolly end up taking it to the machine shop to have them removed.

[loudnlow7484]

Screw extractors? Slot the stud and use an impact screwdriver? Heat it up a little with a torch?

This is what happens when somebody doesn't use anti-seize.

[KatanaBrett]

Harbor Freight has a cheap easy out kit.....

[05RedKat600]

Harbor Freight has a cheap easy out kit.....

And it's worth exactly what you pay for it......