Exhaust rot removal help Gt125r 2016

[Thomas]

Bike Model = : Gt125r 2016

Hi everyone

 

I have an extremely rotten front header on my GT125r that I have no idea how to remove. No one local wants to touch it.

The front down pipe has rotted through the outer pipe and the collector has a massive hole in it. I can get a new exhaust system but I cannot get this one off due to the rotted nature of the security torx.

Any advice would be greatly appreciated, I have attached a photo of the rotten pipe and the hardware so you can see how bad it is.

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[AllanA]

You could try this.  Plenty of WD40 on the rusty fixings and leave it to soak in overnight.  Use a hacksaw to cut through the rusty exhaust close to the cylinder head but be careful not to damage the fins. That will provide more room to work on those rusty fixings.  The hex head may undo using a ring spanner or socket.  If that fails us a good quality mole grips.  The Torx will be more difficult but if it won’t undo with a Torx key or socket you may be able to grip it with the mole grips. Drilling it out is another option but if you don’t know what you’re doing you can cause more damage!

Bear in mind that debris is likely to enter the exhaust port so you’re going to have to remove the head and vacuum any debris off the piston crown and out of the port.

Let us know how you get on!

[Thomas]

Hi Allan

Thanks for your reply.

The hex head does move I tried earlier and it will turn. Unfortunately the torx one is that rotten I can’t get a torx bit in it. And with regards to mole grips there’s nothing to grab as the access is recessed into the fins pictured below.

I think the only viable option is to drill it out but I don’t have the tools nor expertise to do that and the local garages I’ve spoken too don’t want to touch it incase they screw it up.

I’ll try and clean the torx head as much as possible and see if I can hammer a bit in. Otherwise I feel she may be sold for parts

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[♠️ MARCEL]

I had to do this to a customer bike 2 weeks ago for his MOT would fail on those pipes. Before adding him some Black Widow SS pipes,   the torx bit is a T40 Security Dot Torx   (torx bit with a hole in the middle)

If it rounds off ,  then find T45 (the next one) or T50  === > wear gloves and have a LOT of patience ==> Hammer the Torx bit inside until it is firm and hard.

Once it is firm and hard inside, then you have ONE good shot to turn it!

If not ,  can you get a mobile welder around to come over and weld a torx bit to the bolt ?

Don’t scrap her, you can do this.

Like my other lad ,  his garages ran away from the sight of his bike and because it’s a “Hyosung”  but they are happy to work on a chinese “lexmoto?”  , morons tbh lol.

// Meditation doesn't mean you have to sit still....

[Thomas]

Thanks Marcel

I’ll try and clean it up and smack a security torx in. Hopefully she will turn. I’m slightly encouraged because the hex nut turns.

I also didn’t think of the idea of welding the torx bit into the bolt so I may try that if all else fails.

Either way she will.be off the road as she is out of MOT.

She needs a new horn and number plate light along with the exhaust fixings to pass.

 

On a positive note I did a compression test if her the other week and had an evening 160 psi on each cylinder so the engines good at least 🤣

[Author]

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