How to Remove Rusted Exhaust Manifold Bolts On Motorcycle

HELP STUCK EXHAUST BOLTS: Bike Chat. Last time I did this on a 1200 Bandit engine I ended up having to get the exhaust manifold bolt holes welded up and re-tapped.. For anyone reading this I can only suggest that if you buy a Bandit one of the first things you do is remove each bolt in.

A rusted, seized bolt or nut can turn an easy project into a nightmare. In fact, mechanics have been known to hold a lucky rabbit’s foot or refuse to work on Friday the 13 th for that very reason.. But removing a stuck bolt doesn’t rely on luck-it relies on the proper preparation and tools.

“It was fresh from Texas and rust free,” he recalls. At the rear, Miller decided to stick with the original 12-bolt axle, which is fitted with an OEM Positraction centersection and 3.73:1 gears..

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And, the frustration comes in the form of rusted stuck exhaust bolts. This usually happens in the automobiles because of the corrosion and aging of the nuts and bolts. The rusted exhaust bolt never moves or bidges easily and one might have to apply certain methods to do so.

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Re: Rust Removal from Manifold Last summer my 81 140 was running hot so after many hours of trouble shooting i discovered that my manifold was pluged, a differant engine which was laid up for a few years, I removed the riser and it looked good there. So I removed the manifold and with a coat hanger and a high pressure washer I cleaned it out.

I bought a unicorn of a motorcycle. this wasn’t kind to the exhaust’s appearance. Oxidation had taken hold and surface rust had developed. The only way to do a proper job of cleaning the exhaust.

Bare cast steel is going to rust, all the quicker when you add exhaust heat. So while the rest of the engine bay looks great, the exhaust manifolds are often rusted and grungy. And as we all know.

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Re: Rusted Manifold Bolts?? This may sound a little scary, but I’ve done it several times. 1. Remove exhaust elbow 2. place a large diameter pipe into exhaust opening 3. Strike pipe with sledge The manifold is cast, it will snap at the bolts The bolts can then be easily removed with vice grips

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