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[Webby the Bear]

Hi guys,

Me and the Mad Mechanic went to do my exhaust a couple of weeks ago and found the downpipe to centre silencer bolts were, as expected, not going to budge.

Tomorrow I have the full use of the workshop to do work on my car 

I was going to do it with the acetylene torch to heat up the flange(s) cherry red, then buzz gun the bolt out.

IF not is hacksawing them off and replacing an option? If so can someone baby-step me the procedure?

Thank you.

[Webby the Bear]

Ps, are the exhaust clamps going to give me any grief (the ones that attach the centre silencer to the rear silencer)? Or will I have to saw these off too? 

[TheBoy]

Use a socket/spanner rather than impact wrench.

If you shear it, you'll have to drill and retap (preferred) or drill and nut and bolt it.

[Webby the Bear]

Thanks TB.... so heat is the way to start then ratchet it off?

If they still won't budge is the hacksaw a way to get them off.... or is it just drilling the only option?

[YZ250]

Ps, are the exhaust clamps going to give me any grief (the ones that attach the centre silencer to the rear silencer)? Or will I have to saw these off too? 

What are you actually renewing, all or part of the zorst? 

[Webby the Bear]

Ps, are the exhaust clamps going to give me any grief (the ones that attach the centre silencer to the rear silencer)? Or will I have to saw these off too? 

What are you actually renewing, all or part of the zorst? 

I've got a full cat back system kindly donated by NickW. However the other exhaust pipes are actually in good condition so I'm just (for now) going to replace the part that's bad which is the drivers' side centre silencer.... it just so happens that its that side that the fasteners are stuck in  the other side came out ok.

[DaveA]

  Hi Webby
 When I did mine the studs sheared off flush to the flange, did as TB said drilled studs out and replaced with bolts and copper covered nuts

[biggriffin]

Am assuming you are fittin a complete system,if so ignore the rear.
1st clean up with wire brush dwn pipe to system bolts.
2 get 12/13mm sockets n spanners ready
3 light the blue spanner
4 heat each bolt till nice n red
5 try to undo said bolts
6 when bolts removed,take whole system off as one piece.
7 drill out dwn pipe flange to 5\16or 8mm
8 fit new system,use some  exhaust sealent on flanges,and were tail section joins,line up,and check clearance on rear wishbone then tighten up..

if the bolts snap in the dwn pipe flanges then you will need to drill them out using a 2-3mm drill to start as a pilot then drill out to 5/16-8mm.

use m8x 75 nuts n bolts and washers to refit dwnpipes to system..

[YZ250]

Ps, are the exhaust clamps going to give me any grief (the ones that attach the centre silencer to the rear silencer)? Or will I have to saw these off too? 

What are you actually renewing, all or part of the zorst? 

I've got a full cat back system kindly donated by NickW. However the other exhaust pipes are actually in good condition so I'm just (for now) going to replace the part that's bad which is the drivers' side centre silencer.... it just so happens that its that side that the fasteners are stuck in  the other side came out ok.

 If all, then only the front flanges matter as you can get the rest off complete. If part, the middles and rear box grow to love each other and don't take kindly to being seperated. 

[Webby the Bear]

Thanks guys. Appreciate the help! 

I'll let you know how I get on

[terry paget]

It's worth persevering with the blowtorch to get the old bolts out, because drilling the bolts out is difficult. Get the flange good and cherry red, let it cool, spray with oil and gingerly turn the bolts with a spanner. If they won't turn with modest force, get them hot again, and try again. When they turn a bit, spray with oil, turn them back and forth to work the oil in,then gradually undo them. When they are out, clean out the threads in the flange, use new stainless steel bolts and copper ease grease on reassembly.

[Webby the Bear]

BG, that's a great explanation, thanks mate. so basically I only need to concern myself with the four bolts then just off the hangers and remove it as a whole unit 

[Webby the Bear]

Thanks Terry 

[terry paget]

Concerning the back box, it will come off. I have just changed mine while changing my clutch. With the system off the car, remove the clamps (unscrew or hacksaw) and discard, then heat the length of overlapped pips with the blowtorch. Then with luck you can hammer the rear box off the pipes. If not, hacksaw the outer pipe in line with the old grooves, spray in oil, and try again. If no joy, heat it again. It will come off eventually. It's better than buying new central sections unnecessarily. It's a job I find very satisfying.

[zirk]

Your probably end up drilling the bolts on the Downpipe, so for the sake of a few pennies get some Stainless Steel Nuts and Bolts to replace.

Makes it a lot easier next time for you or someone else.