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Discussion Starter #1
OK. I bought some turn-downs for my exhausts a while back. I can't get the bolts out to remove the old OEM tips. They are rusted enough that a wrench won't even think of removing them. I used Liquid Wrench prior to trying to remove them. The bolts just sat there and laughed at me as the bolt-heads crumbled away.
Is there a relatively easy way to get the exhaust pipes off so I can drill/extract the 8mm bolts that hold the OEM tips on?
Anyone have any pictures of the easiest way to do this? I don't have a lift, but I can get a spot in the Ft Belvoir Craft Shop...hopefully.
 

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Loosen the muffler clamp at the front of the muffler(s). Remove the hanger bolt under the bag holding the muffler in place. Wiggle the muffler and pull backwards.
 

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Discussion Starter #3
Thanks, Red! I knew one of you guys would give me a reasonable alternative. YOU DA' MAN!
 

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Try heating the bolt with a torch, not red hot just real hot. While it is hot, whack it a couple of times on the end with a hammer. Should jar the rust loose enough to remove.
 

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I twisted the heads off the screws with a socket wrench. The first one was by accident. After pulling the old exhaust tips off, I then pulled the entire muffler off the bike and drilled the screws out of the nut. BTW the nut is welded inside the muffler. Then I used a thread chaser to smooth out the threads. The new screws went in easy a can be. Oh yes I put some anti sieze compound on the new ones. I did this on a 2002 with about 30,000 miles on it. The entire process took about two hours including going to the hardware store to buy new screws.
 

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Discussion Starter #6
Thanks for all the good info. I'm planning on doing it this weekend. Hopefully, it will look better for Hendersonville. Mine is an '02, also. It's got 72,500 on it. I don't get out much. LOL!
 
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