Exhaust bolt replacement?

[Gorminrider]

I've had poor results with heat...mostly because my puny butane torch just gets dissippated so easily outdoors on an engine designed to dissipate heat. But it burns off the penetrating oil nicely. I'd think the best success with heat is going to be a real acetylene torch with a fine tip.

[Grimly]

I've had poor results with heat...mostly because my puny butane torch just gets dissippated so easily outdoors on an engine designed to dissipate heat. But it burns off the penetrating oil nicely. I'd think the best success with heat is going to be a real acetylene torch with a fine tip.

I seem to recall someone igniting a magnesium casing with an acetylene torch. Not likely to happen here, though.

[oldskull]

So after several days of liberal application of Liquid Wrench and tapping the bolts and collars with a punch and hammer I gave it a go. I used a six point socket and turned them a tiny bit clock wise then reversed.

Drumroll please... they all loosened without issue. Yay! I haven't taken them all the way out yet but am considering just inspecting them and if they look good, cleaning them up, and reinstalling with anti-seize (aluminum based) and then upgrading a bit later. What are the recommend stud or bolt options?

[Rich82GS750TZ]

Great news. The exhaust gaskets are single-use crush washers and may not seal tightly again if you loosen all the bolts, put on some anti-seize, and reinstall. Then again, they might. You’ve been lucky so far.

[xkaes]

You've given me hope for when I tackle my own nuts and bolts!!!!!!!!!!!!!!!!!

[rphillips]

Congrats skully, seems like your lucky day. I love folks not having problems. If using studs, just from a hardware store. Get same dia., length, & thread. If you'd rather be more exact, check the "70"'s & early "80" 's Kawasaki KZ 1000 & KZ1100's exhaust studs. I know we've used studs from a non Suzuki & I think those are the ones & should be an exact fit. But get "ONE" first just to be sure.

[roeme]

So after several days of liberal application of Liquid Wrench and tapping the bolts and collars with a punch and hammer I gave it a go. I used a six point socket and turned them a tiny bit clock wise then reversed.

Drumroll please... they all loosened without issue. Yay! I haven't taken them all the way out yet but am considering just inspecting them and if they look good, cleaning them up, and reinstalling with anti-seize (aluminum based) and then upgrading a bit later. What are the recommend stud or bolt options?

I've put run-of-the-mill stainless steel ones into mine, with liberal application of graphite-based anti-seize. It worked fine so far, but I haven't had to take off the exhausts too much since, and I don't drive when the environment gets corrosive (salted streets sometimes during winter).