Sprocket & Chain help

[GS650E_81]

Well I messed up pretty good...

Last night I jumped the gun and thought I would have to remove the exhaust to get the axle bolt out.. So I preceded to remove the exhaust hanger bolts and the exhaust...partially.

The header was about half way off the I realized I did not need to remove the exhaust at all, just turn the chain adjuster upside down and the wheels pops off easily.....silly me!

NOW, I cannot get the header back into the engine for nothing. I used a rubber mallot to try and knock it back in, but no luck. I can see this will cause an exhaust leak...

Is there a trick to getting this thing back in????

[Gonzo]

Don't force it! That's a good way to rape your threads and then you'll have a REAL problem.

I recall my exhaust bolts being pretty rusted up and some time with a wire brush or wheel would help a lot to clean them back up. If they won't start to thread, do not force them or you'll probably cross thread them. Some penetrating spray and patience will likely be your best friends here.

I imagine if you're running stock exhaust, that you needed to take the exhaust off to get the axle bolt torqued again. I had to anyway. Getting the tire off is not an issue with the exhaust on, but you simply can't get a torque wrench in there. So basically, in my opinion, the exhaust had to come off sooner or later. No flub there.

[GS650E_81]

Don't force it! That's a good way to rape your threads and then you'll have a REAL problem.

I recall my exhaust bolts being pretty rusted up and some time with a wire brush or wheel would help a lot to clean them back up. If they won't start to thread, do not force them or you'll probably cross thread them. Some penetrating spray and patience will likely be your best friends here.

I imagine if you're running stock exhaust, that you needed to take the exhaust off to get the axle bolt torqued again. I had to anyway. Getting the tire off is not an issue with the exhaust on, but you simply can't get a torque wrench in there. So basically, in my opinion, the exhaust had to come off sooner or later. No flub there.

The exhaust bolts are not the problem. The problem is the header will not go all the way back into the engine. When I was pulling the header out it was super tight. Now it won't go back in all the way. Is it safe to put the bolts in some carb cleaner overnight?

[Gonzo]

It's all metal, it won't hurt it.

[mrbill5491]

Sounds like you tweaked the exhaust tubes just a bit. Might just need some muscle to get them back in alignment.

[7981GS]

There must be a dozen GSR members near you in Ohio.
Perhaps one (or more) of them could take a look and help you?

Eric

[Steve]

There must be a dozen GSR members near you in Ohio.
Perhaps one (or more) of them could take a look and help you?

Eric

Just in case you hadn't noticed, my location has been updated.

.

[7981GS]

Just in case you hadn't noticed, my location has been updated.

.

Your current location, seems to be nation-wide most of the time.

Eric

[Steve]

Your current location, seems to be nation-wide most of the time.

Eric

So far, just the east side. The last four years have all been east of the Mississississippippi River.

.

[cowboyup3371]

GS650, give me a shout sometime. I wouldn't mind riding down to lend a hand and actually need to look up Dogma anyway (he's in your neck of the woods) to get something here soon.

[GS650E_81]

Well, I got both the front and rear tires off. I am going to pull the rotors from the front today and spray paint the rims, then go get some new tires.

As for the exhaust, still a no go. I think I may have to buy a ratchet strap and try that method.

Cowboyup - Where about's are you located? I am on the west side of Ohio, about 20 minutes from the Indiana border.

[cowboyup3371]

I'm here in Dayton

[1_v8_merc]

Did you get a clip-on Master Link, or Rivet?
If you have a rivet, you'll need a rivet tool, or Harbor-Freight chain breaker tool(which can do both, just YouTube it) Either way, make sure you go Easy and don't smash the rivets too hard, or the Master Link will pinch too tight on the chain.
Just tighten the rivets down, one at a time, then pull the tool off, inspect the rivet, and tightness, then re-attach the tool, tighten it down a little more, then re-inspect.
(remember, if the rivet isn't fully pressed down, you can always re-tighten, But if it's too tight, you can't go back and loosen it.)

[GS650E_81]

Did you get a clip-on Master Link, or Rivet?
If you have a rivet, you'll need a rivet tool, or Harbor-Freight chain breaker tool(which can do both, just YouTube it) Either way, make sure you go Easy and don't smash the rivets too hard, or the Master Link will pinch too tight on the chain.
Just tighten the rivets down, one at a time, then pull the tool off, inspect the rivet, and tightness, then re-attach the tool, tighten it down a little more, then re-inspect.
(remember, if the rivet isn't fully pressed down, you can always re-tighten, But if it's too tight, you can't go back and loosen it.)

Clip-on master link.

My old chain has a master link as well, so I am assuming the PO changed it out at some time, but when I went to remove the clip it was seized on. I had to dremel it off and the chain just fell apart...Glad I purchased a new one!

[GS650E_81]

Bike on stand and cheap-o jack.

I hope to get new tires today and mount them tomorrow.