Straightening Bent Exhaust Flanges

Print
User Rating: / 24
PoorBest 
Written by Randy Fox (Randysgym)   
Monday, 02 March 2009

Tools Needed

 

8mm Allen wrench -- for the exhaust header flange nuts, preferrably with long reach

Sockets, screwdriver, or other simple tools -- for the other fasteners of your pipes, depending on the make and model of your exhaust system

High-Temp silicone gasket paste -- (tube), optional, for sealing the exhaust header gaskets. Note: I have used Versa-Chem Mega Copper, high-temp silicone gasket maker from my local auto parts store

 

----- If Your Exhaust Header Studs are Bent or Damaged -----

Hammer -- for 'straightening' exhaust header studs, as needed

Cold chizel or punch -- for 'straightening' exhaust header studs, as needed

Vise-grip pliers -- for removing exhaust header studs, if needed

Regular pliers -- for removing exhaust header studs, if needed

Dremel rotary tool -- (or other) for cleaning out the exhaust header stud holes in the head(s) if needed, and/or cutting studs or flanges if necessary

Safety glasses and ear plugs -- for protection while using Dremel (rotary) tool or other power tool, as needed

Thread-lock liquid -- if exhaust header studs will be replaced

Torque wrench -- optional, for installing exhaust header studs, if needed

 

----- If Your Exhaust Heat-Shields are Removable -----

Smooth-jaw vise, large -- or two thick board pieces (like 2"x8"x16" or more), for straightening removable type exhaust header flanges, if yours are this type. as needed

 

----- If Your Exhaust Heat-Shields are NOT Removable -----

Sturdy board piece -- like a 2" x 4" wall-stud at least 12" long or more, for straightening non-removable type exhaust header flanges, if yours are this type

Small set of open-end wrenches -- (Qty: 2), for 'jacking' the flange back to its original flatness

'C'-clamps -- (Qty: 2) 4" to 6" or so, to clamp the exhaust header flange while bending it back flat. They must be large enough to spand the exhaust header, flange, and the board; and they must be small enough to fit the opening between the heat-shield and header flange. See the clamp-jaw and heat-shield clearance in the upper right area of the photo below.

 

Yamaha roadstar exhaust flange fix bent jack straighten

 

Homemade, miniature pressure jacks, as follows:

  • Bolts: 6mm to 8mm shank, (or 1/4"). (Qty: 2) -- to use as miniature 'jacks' for bending the exhaust flange flat. See 'jack bolt' in the photo above.
  • Nuts: Non-locking type. (Qty: 4)) -- to use as pressure 'jacks' for bending the exhaust flange flat. See photo above.
  • Smooth Washers: Thick, with hole to fit 'jack bolts' described above. (Qty: 2) -- to be used against the exhaust flange. See photo above.
  • Small sturdy metal scraps: Any heavy gauge (16ga or less), flat metal pieces, such as large fender washers. (Qty: 2) -- to use as base-pads for the miniature jacks for bending the exhaust flange flat. See 'scrap metal' in the photo above.

 
...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... -->

 



The Road Star Clinic is a collaborative community of riders who archive and publish user contributed technical data about Yamaha Road Star motorcycles.

We also sponsor the creation and support of other community websites similar to our own. Inquiries about availability of a website for your community can be submitted to us via any "Contact Us" option on the Clinic.

Copyright 2003-2007 Road Star Clinic and its respective authors. Road Star Clinic is sponsored by the folks at MLSHomeQuest.com.