New (well like new) Exhaust system!!!

[Anonymous]

Well it took about a year, but I finally snagged a great looking stock 4 into 2 exhaust for my GS1100GZ! Whooo who! I have had this Kerker 4 into 1 system since I got the bike, but the carbs weren't rejetted to match the exhaust. When I switch back to stock, I'll start looking for some decent Vetter saddle bags that now don't fit on the bike because of the Kerker position....

Anyway, anyone have suggestions on loosening those exhaust attachment bolts? I have this vision of at least one of the rusty buggers snapping when I try to unscrew them... I plan to soak them with a lot of WD-40 and spray on some Marvel Mystery Oil. Let it soak in and then cross my fingers!
GY

[Anonymous]

Hi GY,
I would give them a good beating with a hammer before I tried to unscrew them. An impact gun set to low may help jostle them loose too. If you can't get them all off at once you should reattach the exhaust with some new bolts and have at it again the next evening. I bet you'll have better luck if you work on the header while the engine is still hot too, but you'll have to be careful.

If you are in a big hurry you'll just make a big mess.

Steve

[Anonymous]

Hey Gerry,

Just to tell you about my experience with these bolts... Well I haven't had any luck successfully removing all the bolts without breaking at least one. This happened to me on two occasions...The first time was when I had to disassemble the top end because it needed some valve work. The next time was on a donor bike. On both occansions I tried soaking with WD-40, PB Blaster, and heat and I still broke some bolts. All I can say now is that Im getting pretty good at drilling and tapping.
So to prevent this from happening again I installed studs and since then I havent had any problems.

So, if your exhaust hasnt been off in awhile (lets say years) and there is noticable corrosion you might run into this problem.

Well Good Luck

[mcycle-nut]

To avoid future problems, make sure you coat the bolt or studs with Nev-R-Seize. 8)

[Anonymous]

To avoid future problems, make sure you coat the bolt or studs with Nev-R-Seize. 8)

I even use that stuff to lube the shift lever on my bike-i used it on my boat in salt water for years--It works well.

[Anonymous]

Yea, I get all sweaty just thinking about those bolts breaking on me. I almost want to just take the bike and exhaust system to the shop and say here ya go boys, change it for me... But then I am a lazy guy. I'll have to ask them for a quote for how much it would cost me. I don't really want to use drills an Easy Outs if I can help it!
GY

[Clone]

LIQUID WRENCH!!! give them a blast with this stuff a couple of times on the days leading up to when you want to work on them. It does a t
great job softening up the rust.

[Anonymous]

I HATE BREAKING BOLTS!!! sorry... after reading this it kinda made me *@%^$*@%^$*@%^$*@%^$ed off. My bike has been sitting in the basement now for a month all disassembled and I have yet to ride it since I got it. well, I finally got everything reassembled yesterday and I was putting the rear wheel back on. Got it on and went to adjust the chain tensioners when SNAP! Broke one of the bolts clean off. I was sooo *@%^$*@%^$*@%^$*@%^$ed off. I was finally going to get to take her for a spin around the neghiborhood, and now I have to wait till I find the time to get a new bolt!

Funny thing is that I didn't even meet any resistance. On the first turn is just snapped right off. Then I tried grabbing the end of it with a pair of pliers to get it out, and those snapped too!! I also broke ofe of the screws that hold the throttle handle on. Luckily It didn;t break off too far in and I was able to get it out with a pair of pliers (before I broke them).

[Don Lobacz]

Yes, heat and lube are necessary. If you get one to move but then it binds up tight, lube it again and take it back in gently - this back and forth technique slowly carries the lube into the threads. If the bolt breaks, DON'T even try using an EZ-out of any kind! 7 out of 8 times it will break and then you have a drilling nighmare. The shop here in town recommends using a roto-bur tool to clean out the old bolt, overdrill and install a helicoil. Drilling it out goes faster but you can never get the hole directly centered in the bolt, and so you end up with a metal sliver on one side of the hole, and that doesn't tap well. Another trick is to loosen the motor mounts and move the hole away from the frame so that you can get directly at it.

[Pillage]

Re: New (well like new) Exhaust system!!!

Well it took about a year, but I finally snagged a great looking stock 4 into 2 exhaust for my GS1100GZ! Whooo who! I have had this Kerker 4 into 1 system since I got the bike, but the carbs weren't rejetted to match the exhaust. When I switch back to stock, I'll start looking for some decent Vetter saddle bags that now don't fit on the bike because of the Kerker position....

Anyway, anyone have suggestions on loosening those exhaust attachment bolts? I have this vision of at least one of the rusty buggers snapping when I try to unscrew them... I plan to soak them with a lot of WD-40 and spray on some Marvel Mystery Oil. Let it soak in and then cross my fingers!
GY

Hey Gerryy,
Have you swapped exhaust systems yet? I'm curious as to how you made out because I want to swap my rusted 4 into 2s for a decent 4 into 1. BTW do you want to sell the old Kerker? I think it would fit on my bike?
Andy

[Anonymous]

Hey Andy, no, I haven't swapped them yet. This warmer weather has caused a delay in the winterizing plan
ANyway, I will be doing it in the middle of the winter anyway as I am now trying to bundle up the house and get the wood chopped and stacked. you know that other fun stuff that doesn't include motorcycles :?
ANyway, I will let everyone know how it turns out!
Wish me luck...
GY