intake manifold bolts stuck help!!!!

[rampimpin]

im trying to get the intake boots off my 82 gs1100g. they appear to be the stock boots on the bike hard as a rock, one pulled clear off the motor bolts still in the block still. my problem is im buying a newer set and i tried to get the old ones off and the bolts feel like there gonna strip so i stopped.but there stuck any help would be great

[cowboyup3371]

PB Blaster or similar lubricant (NOT WD40) on each one and an impact driver.

[rampimpin]

i put some slick 50 on it over night havent tried yet today. ill have to look into and impact driver will that be able to fit into the frame? never used one but will try it ive put to much in the bike for this to stop me!!

[londonboards]

Exhaust Bolts Removal

Hello I have the exact same bike and did have the same problem a few weeks ago. Here we go:

http://www.thegsresources.com/_forum/showthread.php?p=1743803#poststop

Also look at my blog is you are doing a GS1100G:

http://suzukigs1100.blogspot.co.uk/2012/10/exhaust-bolts-day-44.html

http://suzukigs1100.blogspot.co.uk/2012/10/exhaust-bolts-part-2-day-54.html

http://suzukigs1100.blogspot.co.uk/2012/10/exhaust-bolts-out-day-55.html

When looking at the blog, click on the main starter picture to go the latest postings.

I also put together a GS1100G (also included GS1000) list of great threads on this forum that you can use as a good reference:

http://www.thegsresources.com/_forum/showthread.php?t=202497

Lets see some of your pics.

Good luck and greetings

[chuck hahn]

If your impact driver has the removable tip thatn holds the bits, then just take out the battery and add as many extensions as you need to get to the bolts with the impact outside the box..run the extensions down thru the frame to the bolts. Get rid of the cross tip bolts and add in the stainless allen head style and youll not have the problem again.

[almarconi]

Try heat and an impact driver. Without the proper tools you will just mess up the screw head.

[mike_of_bbg]

If you can get one screw off then you can probably hit the boot counter-clockwise with a hammer to loosen the other.

[chuck hahn]

I would watch heating anything around the intake boot....dont want to ruin the rubber on it..just saying. Last thing you want to do is start the rubber on fire!!! Or melt it.

[chuck hahn]

I cant find the thread with the pic..but someone posted a pic a while back of them doing the extension thru the airbox / frame area. Thats really the best way I have found for the cross tip screws..snaps them loose right off and then you can get them out of the system for good. I have tried the get one out and tap the boot around thingb too..just to have the boot slide but the screw not untwist or break loose.

[almarconi]

I would watch heating anything around the intake boot....dont want to ruin the rubber on it..just saying. Last thing you want to do is start the rubber on fire!!! Or melt it.

A torch with a pencil flame works well. Obviously you want to keep the heat on the bolt and not the boot. Some of the newer bikes have loctite on the bolts and you pretty much have to heat them up to get them off.

[chuck hahn]

You can get even Loctited bolts out withn the right setup and no heat..just takes more finesse and patience.

[rampimpin]

thanks guys i will give it a shot im hoping for the best

[Bonehead]

Just did this yesterday, and some PB and an impact driver do wonders. Let the PB set for a little while, and then give it a go with an impact driver. Be warned though, I ruined the philips head on the impact driver (Thank god for Snap-On's warranty).

[Larry D]

I used a pair of needle-nosed vice grips. Start with the #4 boot because it's easily reachable with the grips. Use PB Blaster and soak the bolts for a day or two. Grip the rightside #4 boot bolt and work it back and forth slightly to break it loose. The other (left) bolt in the boot can be broken loose by turning the entire boot counterclockwise. Once #4 is out, continue with #3, etc......You'll ruin the bolts, but, they should be replaced with socket heads anyway.

[Lowflyer]

im trying to get the intake boots off my 82 gs1100g. they appear to be the stock boots on the bike hard as a rock, one pulled clear off the motor bolts still in the block still. my problem is im buying a newer set and i tried to get the old ones off and the bolts feel like there gonna strip so i stopped.but there stuck any help would be great

tig welder, bolt,
socket wrench to match. No muss no fuss.