Removing headers from cyclinders

[KDeline]

R1200RTP, 2009, 100,000 miles. I am changing out the header as I found a huge crack at the weld. (Maybe this was why the bike ran poorly?) Is there any wisdom from the group as to the difficulty of removing a header from the cylinder? Looks straight forward, just wondering with all the heat on the bolts that hold the pipes on if there is any trick or problem there could be.

[dirtrider]

2 hours ago, KDeline said:

R1200RTP, 2009, 100,000 miles. I am changing out the header as I found a huge crack at the weld. (Maybe this was why the bike ran poorly?) Is there any wisdom from the group as to the difficulty of removing a header from the cylinder? Looks straight forward, just wondering with all the heat on the bolts that hold the pipes on if there is any trick or problem there could be.

Afternoon KDeline

 

It can depend!  Sometimes the header nuts will just come right off & other times they can be rusted tight enough to snap the studs off.

 

Don't use excessive force to try to remove, if they really fight you, or feel like the nuts are going to twist the studs off,  STOP!

 

Then carefully drill a small hole in the front of the nuts (on center) then squirt in some penetrating oil, then start the engine & allow the pipes to heat up (hopefully that wicks the penetrant in). Then as they are cooling spray more penetrating oil into the drilled holes. Then try removal again.     

[KDeline]

Yeah, just imperceivable little crack. 

[Hosstage]

A little JB Cold Weld ought to fix that right up!