K11 Owners Group

Tony627 · Joined: 21 Jul 2010 Posts: 20 Location: Kent, England

Hi all

I am after a little piece of advice. I have a K1100 1995. The exhaust has fractured. I have removed to bottom half of the fairing to gain access to the exhaust manifold bolts and I have found them to be VERY corroded to the point where they are rotting and the nuts and studs appear to be as one, fused together. Any thoughts about how to remove the nuts/studs would be welcome.

Best wishes
Tony
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1995 K1100LT alias 'Big Red'

Scott_Anderson · Posted: Sun Aug 17, 2014 10:10 am Post subject:

You try some penetrating fluid, but don't be surprised if you have one or 2 studs stay stuck to the nut and thread themselves out of the head instead.

It's not unheard of to have one break also.

As you prepare to remove the system, don't forget to have some new crush ring washers for the manifold mating joint, where the tubes meet the head.
You could maybe get lucky and have the existing ones seal again when you re-install the exhaust, but if they don't then you are back to square one and removing the exhaust again....
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1995 K1100LT 0302044
2017 FLHTK Ultra Limited
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1997 K1100LT 0302488(R.I.P.)
1997 R1100RT ZC62149(sold)

Flying Duck · Posted: Sun Aug 17, 2014 11:04 am Post subject:

Wouldn't hurt to run the bike up to operating temperature or use a torch on the bolts to heat them up prior to attempting to loosen them.

Of course if you use the prior method then be careful not to burn yourself on the headers.
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552255 · Posted: Sun Aug 17, 2014 11:53 am Post subject:

If your talking "fracture", at the 4 pipe junction area, you DO NOT want try and weld it off the bike...it will pull the pipes out of alignment, and you can't get the exhaust back on the bike...been there done it...not fun.

Weld the cracks while on the bike as best can be done, if that's your problem, and then take off exhaust if necessary, etc.

I have had to weld mine twice in that area, but it seems to hold for awhile...each time 'welded' more re-inforce between the 4 pipes, seems to solidify the unit.
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1997 K1100LT-SE
1996 K1100RS-SE
"Black & Silver Duo"
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