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.

[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.

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 ..