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Pete, btw I noticed the disproportions of the front and back on my bike as well. Happen to have an idea of what that would be other then difference in wheel size between the front and rear wheel?
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Given yours is an L, you should (if memory serves correct) have a 19" front and 16" rear wheel... what diameter are they? If the front is off a 650, potentially the forks are longer too...1982 GS450E - The Wee Beastie
1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020
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450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh
Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11Comment
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Amongst other things I have done this weekend, I took off the exhaust. What I found underneath looks like absolute junk. Take a look...Comment
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When I took it off, I found out that the exhaust was held on by 3 different sizes of bolts, with one missing. I didnt know why until I found that the hole was bugged.
What do I do with this??Comment
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That's typical of these old exhaust header bolts.
It looks a bit too far in to do this method, but success has been had welding a bolt or something on to get some purchase and remove it. The heat of the weld can help release it too.
Otherwise, drilling very carefully on the correct angle with a left hand drill bit can get it to budge.
Whatever you do don't use and Easy Out on that... guaranteed it'll be stuck fast and the Easy Out will break off and then you'll have even more pain to deal with.
Worst case take it to a machine shop to get it out.
Once it's clear, use a tap to clear up the threads or if they're completely buggered, you can use a helicoil insert to repair it and get it back to the right size.
Also, a lot of guys have had good success installing studs in place of the bolts so you can tighten the exhaust down using nuts rather than bolts.1982 GS450E - The Wee Beastie
1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020
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450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh
Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11Comment
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Definitely recommend studs in place of the bolts. I had two of the four break off on me the last time I removed the exhaust, (Probably the first time it had ever been removed.)
I used the left hand drill bits which didn't even nudge the bolts so I had to drill them completely out to size and re-tap the threads throughout.
I just took off the exhaust again last night and it came off within 15 minutes and very minimal effort. The studs are fantastic.Comment
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