Removing Motorcycle Exhaust Bolts

After years of extreme engine temperatures, removing exhaust manifold studs can be a near impossible task. rust and corrosion can also fuse.

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The bolt to remove the slip on muffler is located just under the passenger foot peg, and can be removed with the socket wrench. When the bolt is loose, locate the second mounting bolt located between the mufflers which secures the exhaust system to the frame of the motorcycle and remove it, as well.

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I was attempting to remove the mufflers in preparation to wrap the exhaust. I found a few YouTube videos on the process but it seems that Indian made a mounting change on the 2017 Scouts. I cannot seem to unscrew the opposite-side bolts where the mufflers attach to the bike. The bolts are hindered by the connection arm on the bike.

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Exhaust studs snapping is a complete bitch I recently replaced the headers on my ’97 Bandit, each downpipe has 2 studs, and during removal, 1 stud on each header snapped I briefly tried removing them by dremmeling slots into them etc, but they were either too soft or snapped too short.

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Putting cuts on the nut and bolts is a sure-shot method to remove immovable bolts. One can apply suitable force with soft hands for removing rusted exhaust flange bolts in no time. This is because splitting the bolt into pieces reduces the tension in it thus making it simple to rotate and move. Reliable ideas how to remove rusted exhaust bolts.

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Step 3 – Disconnect Exhaust. Loosen and remove the exhaust flange bolts followed by the fasteners that attach the exhaust pipe to the engine. Remove the bolts that attach the muffler to the bracket. The exhaust system is heavy and prone to scratching. Have a helper assist you when removing the exhaust system.