Got a Screaming Demon for my Hyo but the exhaust bolts are rusted shut

[francewavidok]

Hi all,

Got a Screaming Demon to pop onto my Hyo and I tried to take off the existing exhaust. Only to find that the 4 bolts holding it in place have completely rusted. I soaked it in WD-40 then tried to take it off and one of the bolts snapped. The other 3 simply slip and I can't get any grip to get them off.

I am thinking of taking a hacksaw to it and cutting the 4 bolts off in which case i would need 4 bolts to put the screaming demon on. Does anyone have any spare ones lying around? Where would I get these?

Thank you in advance for the help.

[jellywrestler]

if you hacksaw them off then how you going to remove the remainder?
pics would help

[HenryDorsetCase]

If they are bolts you might bet vise grips on them. but yeah, a pic.

[FJRider]

Hi all,

Got a Screaming Demon to pop onto my Hyo and I tried to take off the existing exhaust. Only to find that the 4 bolts holding it in place have completely rusted. I soaked it in WD-40 then tried to take it off and one of the bolts snapped. The other 3 simply slip and I can't get any grip to get them off.

I am thinking of taking a hacksaw to it and cutting the 4 bolts off in which case i would need 4 bolts to put the screaming demon on. Does anyone have any spare ones lying around? Where would I get these?

Thank you in advance for the help.

Bolts of most sizes are available for sale at most hardware outlets.

[buggerit]

STOP!! Take it to a tradesperson now before u make the job alot harder for them and more costly.
They have the gear and experiece, it may cost u a little but save you alot of grief.

[Madness]

^ What he said. Take the bike into an exhaust/muffler workshop would be my advice. Do eet quick before this thread turns into a discussion about how yout Hyobag will no longer be LAMS compliant with the new muffler. :msn-wink:

[francewavidok]

I think it might be time to take it to hyobag and see if they can do anything? But I will post a picture to be sure :)

[FJRider]

^ What he said. Take the bike into an exhaust/muffler workshop would be my advice. Do eet quick before this thread turns into a discussion about how yout Hyobag will no longer be LAMS compliant with the new muffler. :msn-wink:

Being a 250 ... LAM's compliant is the least of his problems. He can replace most of the Hyo's parts with no danger from that legislation.

A wrong choice of muffler however ... may result in issues with what will now be incorrect jet sizes. At best ... an improvement in sound will be the only gain. And as for performance ... it may even be a backwards step.

But no doubt the OP will have already researched all possible problems/solutions with qualified people ... right .. ???

[Akzle]

bro, did you get a new set of muffler bearings with the new one, or are you planning on re-using the old ones?

[FJRider]

bro, did you get a new set of muffler bearings with the new one, or are you planning on re-using the old ones?

Not to mention a power band upgrade ... the blue ones those Hyo's came out with are shite ... <_<

[francewavidok]

Not to mention a power band upgrade ... the blue ones those Hyo's came out with are shite ... <_<

I have done a decent bit of research and know for a fact that the screaming demon will be just fine on this bike - it is just a slip on. All I have is the exhaust that simply fits into the place of the current exhaust. Here is a picture of where the bolts are and where I wish to cut: https://www.dropbox.com/s/mtome53341btm7u/exhaust.jpeg

Is it all starting to make sense now?

[nzspokes]

Our 650 hyobag did the same thing. I just hit it with a bit of heat and put vice grips on. They came out fine after that.

i wouldnt cut there as there was a center pipe on ours.

[carburator]

Do not cut where you have marked...

simply drill the heads of the crap chinese capscrews off and you are home and hosed..

[buggerit]

DON'T hacksaw down that slot , you will fuck the flange that you want to bolt the new muffler up to.
They look like button head capsrews, are you using the correct size good quality allen key (metric, imperial etc).
Sounds like you have stuffed the heads, you may get away with putting some oil based valve grinding paste
on the correct allen key and trying again(works on screws too).
You could cut the heads off with a 1mm cutoff disc on a grinder(carefully)
You may get lucky and get them with vicegrips but I doubt it.
Tack weld abit of flat to the end of the cap screw and wind out with adjustable spanner.
Possibly smack the heads off with a coldchisel with exhaust supported.

[FJRider]

Is it all starting to make sense now?

I'm just wondering why you dont just keep the bolts .... and replace the rest with honda parts.

With recent law changes ... you'll even be able to marry ..

[Laava]

Not to mention a power band upgrade ... the blue ones those Hyo's came out with are shite ... <_<

I think there is now a Maurice Williamson rainbow power band available.
Hellloooo Boys!!!!

[FJRider]

I think there is now a Maurice Williamson rainbow power band available.
Hellloooo Boys!!!!

It only fits honda's ....

[AllanB]

Have a crack at it after you have been for a ride and the muffler is hot.

Farkin Hyobags ..........even the muffler won't come off!

[francewavidok]

DON'T hacksaw down that slot , you will fuck the flange that you want to bolt the new muffler up to.
They look like button head capsrews, are you using the correct size good quality allen key (metric, imperial etc).
Sounds like you have stuffed the heads, you may get away with putting some oil based valve grinding paste
on the correct allen key and trying again(works on screws too).
You could cut the heads off with a 1mm cutoff disc on a grinder(carefully)
You may get lucky and get them with vicegrips but I doubt it.
Tack weld abit of flat to the end of the cap screw and wind out with adjustable spanner.
Possibly smack the heads off with a coldchisel with exhaust supported.


Hmm thoughts on hacksawing the bolt heads off? What I am thinking of doing is taking her for a ride then maybe trying Vice Grips and see if they work. If not then I will try a dremel or a hacksaw on the bolt heads and feel free to tell me if it sounds like a completely stupid idea.


To all the others there, thank you for your constructive advice and yes there are plenty of those who hate hyos but what can I say she is my first girl and I love her to bits :)

[hayd3n]

i guess the new exhaust has threaded holes?? if so
take that to a fastening shop and buy some stainless bolts that fit :)
you may need a new gasket or some high temp silicone to seal the old gasket if reusing

[Akzle]

((drills and easy-outs))

[Laava]

A good pair of visegrips plus using the allen key as well could work?

[FJRider]

To all the others there, thank you for your constructive advice and yes there are plenty of those who hate hyos but what can I say she is my first girl and I love her to bits :)

Then take it to a Bike shop and get it fitted with stainless bolts. No more problems in future.

Continuing with the butchery using incorrect tools ... can only go bad.

[Akzle]

Then take it to a Bike shop and get it fitted with stainless bolts. No more problems in future.

Continuing with the butchery using incorrect tools ... can only go bad.

fuck stainless, copper anitseize is like jesus on exhaust bolts.