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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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Old 14 Dec 2007
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hi everyone i`ve got a 2003 xt and i`m having a real problem removing the header pipes from the head.....i cut them off to give me a handle as it were but then they just twisted off leaving the thick part still in situ.....the head is still on and i`m gonna try some heat...but i1m a bit worried about the frame, electrics, etc...any ideas???
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Old 14 Dec 2007
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in these case a picture is better than a thousand words.

Anyway if your problem is that the heads of the four allen screws are f*cked, the the cleaner solution is to cut the heads using a dremel. Then use the remaining part to take them out. Better not to use the drill option.
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Old 14 Dec 2007
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m8 it sounds like u have the same prob as me and that is that the head of the exaust header pipes (the fat bit that is pulled un buy the brackets to press the gaskets to the head is seized into the head)

if so what i did was use a dremel to cut a slicefrom the inside of pipe to the outside (mind how ya go ya dont want to cut into the head itself) once i had this dont i put a chisel to the pipe and hit it a few taps to let it close in and fill the space that i had just cut thus making the outer diameter of the pipe smaller and breaking it free from the head of the engine

also if this is the case id be thinking of removing the current mounting studs
to replace em with stainless replacements as the originals r a bit on the poor side and i found that after getting the old headers out and the new in that when i went to make a few ajustments that the studs were just waiting to give up and getting them out is fun fun fun once there sheared of flush with the engine

good luck
2002 xt600e
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Old 14 Dec 2007
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Studs rusted?

There's another thread in here about various ways of getting the exhaust studs out of the head - lots about working on steel next to aluminium alloy IIRC.
Do a search for some key words and the thread should be found!!

Good luck,
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Old 15 Dec 2007
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Youre about two months behind me!

I found that the most effective method was two mole grips on the remainder of the exhaust and then worrying it to bits. The first took me over an hour of constant abuse before it came out!

here is where I was which is where you are now!

Heat up the cylinder head, and remember it is designed to take on explosions! Hit the ends at an angle with a hammer, then worry like hell, and do not forget to use a lubricant.

Always remember that it will come out... eventually

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Old 8 Mar 2008
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New to this site and new to my xt600.
It dont take long to start swearing at these exhausts does it...Thanks Mr Yamaha...tremendous design, rusted header pipes and two sheared studs.
How did you get the dremmel inside to cot a slot?
Did you worry about swarf into the bore?
All help greatly appreciated...I'm hoping this is the only bit of cr*p design on this bike...Time will tell

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