Exhaust Header Removal Problem

[ianp5uk]

I'm trying to remove the exhaust headers on my 1200GS but the flanges or whatever they are called are stuck solid on the studs. I can't seem to get anything on them to force them off because they are slightly recessed in the head. I've tried gentle levering but cannot use much force as I'm levering against the aluminium head! Similarly I'm scared to use a lot of heat because of the Aluminium and also proximity of tank and other bits of plastic. I am soaking it in penetrating fluid but I'm sceptical that it will make any difference.

Has anyone had this problem and solved it - without removing the engine!

Cheers,
Ian.

 

[fizzer]

your right to use penitrating oil ,i find plus gas the best,leave it on over night ,then try tapping with a leather ,or rubber mallet,give it a good wiggle too.

 

[ianp5uk]

your right to use penitrating oil ,i find plus gas the best,leave it on over night ,then try tapping with a leather ,or rubber mallet,give it a good wiggle too.

Thanks

What to tap - the header itself?
Been wiggling (yanking) on the headers but no luck so far. Think the studs have welded to the clamps. Have hit the clamps with a brass drift but as recessed can't hit them in the "off" direction, was just hoping the shock might free them but it didn't and I didn't want to hit too hard in case I damage the head.

 

[Deleted account 181015003]

It might be worth using the engine as a source of heat and then giving them a tap just dont burn yourself leave the header nuts on a couple of turns so the header comes loose and does not just pop off

 

[ianp5uk]

It might be worth using the engine as a source of heat and then giving them a tap just dont burn yourself leave the header nuts on a couple of turns so the header comes loose and does not just pop off

I don't care if it pops off!

I'll try this. Wasn't planning on riding it if I do this - the headers actually get very hot idling as there's no airflow. The heat and maybe exhaust pressure might help.

 

[Deleted account 181015003]

Just be careful leave the nuts on a couple of turns so you don’t have to juggle a hot exhaust when you’re not expecting it