Yamaha dx engine removal questions on exhaust

[swampthang]

I'm going to be swapping engines on my dx from a parts bike soon and I need to figure out what to do about the header pipe. I can see myself snapping off the exhaust bolts on both of them:rolleyes: How can I get them out succesfully? I cant take a torch to the head so maybe run the engine to get it warm? Any tricks? What about removing the engine with the header pipe still bolted on? Is that possible?

[dougspcs]

Totally, I just pulled the head on my 225DR and did just that..fear lead me to leave well enough alone. Unbolted and remove the muffler of course..hopefully you don't have a one piece. Take the head out thru the right side.

You could use this opportunity to put the head on the bench and remove them I suppose.

I will finish the piston job and reinstall the head without ever removing the header pipe..

[Yamaha3wheeler]

I took my exhaust header bolts off not long ago. I soaked them in some PB blaster two nights in a row heading out to the garage mulitiple times to drench them. I didn't have any trouble getting them off.

Did you try to break them loose with reasonable force? I guess it's better to be safe than sorry. :)

[swampthang]

I took my exhaust header bolts off not long ago. I soaked them in some PB blaster two nights in a row heading out to the garage mulitiple times to drench them. I didn't have any trouble getting them off.

Did you try to break them loose with reasonable force? I guess it's better to be safe than sorry. :)

No I haven't tryed to remove them yet. I'm thinking multiple soakings with penatrating oil and heat cycles from the engine followed by tapping on the head of the bolts. That is if the engine can not be removed with the header pipe still on.

dougspcs thats great to know you can get the head out with out removing the header!

[ezmoney1979]

I dont know how much room to work there is on this particular model but perhaps you can take a dremel and VERY carefully cut the nut lenghtwise with the stud? Even if you dont get all the way through it should free up some tension and get it hot too. I have done this on other machines with success. But now I see you say they are bolts so I don't make any sence:)

[atc007]

Heat and soak as talked about. You'll be FINE. IF they snap,,you know you've got a way out.

[muthey]

I have taken the bolts off of three with no problem an 85 dx, an 85 dr, and a 83 200k. They all but my dx had lots of corrosion and rust on them. In my opinion the yamaha setup is more sound than honda's