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Help GJ72A Exhaust header plate/flange/gasket removal

Discussion in 'Suzuki 250cc In-line 4's' started by Zippy, Nov 29, 2020.

  1. Zippy

    Zippy Active Member

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    Hi all.

    I'm hoping anyone who has been through this before would be so kind as to provide me with some guidance...

    Removing the exhaust from a GSXR250, I've got (most) of the manifold bolts out intact. There are however some metal inserts which seem to press-fit the header pipe into the exhaust port.
    Shown as number 3 in the below diagram:

    item 3.JPG

    They're called 'exhaust plates' (Suzuki part no. 14155-04a00), in addition to the circular metal gasket which sits behind them.

    I'm wondering how best to remove these exhaust plates, which I assume enables removal of the headers from the engine.

    Knocking the headers sideways with a hammer isn't dislodging anything, to the point where the rusted exhaust pipes are at risk from being hit any harder.

    Using a screwdriver to try and chisel them out isn't making much impact.

    As you can see, everything looks quite well "embedded"!

    pipe1..jpg

    Is the semi-circular cutout in the exhaust port part of the solution?
    Do the exhaust plates need compressing to be removed?

    Any wisdom grately appreciated!
     
    Last edited: Dec 2, 2020
  2. kiffsta

    kiffsta Senior Member

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    basically the exhaust plates are used to wedge the header pipe against the exhaust gasket \ head and are then held on by retainer plate shown as number 2 on the diagram. Once you have removed the bolts holding the plate ( item 2), the exhaust should come out, as yours have rusted, they will be wedged in and will be difficult to remove.

    I would spray the exhaust plates ( number 3 on the diagram) with a penetrant such as WD40 several times over a 24 hour period. Then I would put something under the exhaust so it doesnt fall to far once it comes out, then undo all the bolts holding the muffler and header to the bike, then grab the muffler and make small up and down movements ( only a few cm's at a time ) which should start loosening the exhaust plates, the headers and plates will fall out.

    WD40 is your friend.

    You will need some help refitting the headers, those plates are a real pain to do on your own.


    clamps.jpg gsxr250.PNG
     
  3. Zippy

    Zippy Active Member

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    Thanks for the knowledge Kiffsta.

    With the bolts removed, the pipes are still very much lodged in the exhaust ports by those rusted exhaust plates!

    Wasn't sure whether they'd need heating to remove or chiseling out, but this weekend I'll be trying your approach of WD40 and moving the system by the muffler end.

    Will report back!
     
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  4. Zippy

    Zippy Active Member

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    Well, after an hour of lubricating and pipe wiggling... there was partial satisfaction!

    plates1.jpg


    Managed to free the pipes and plates from the outside cylinders 1 & 4 using the Kiffsta method and some sideways hammering.

    After seeing there was at least some movement in the plates, using the handle of a hammer between the exhaust runners and the frame was a good way to leaver the pipes away from the engine. Especially on the seemingly stronger lumpy bits of the exhaust pipes.

    hammer.jpg


    Continued WD40 soaking does seem to be the key, especially around the semi-circular cut-outs on the head where the pipe seats into it, as you can almost get the spray behind the plates at the point.

    pipe2.jpeg


    Obviously I'm looking forward to another session this weekend.

    :prankster:
     
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  5. kiffsta

    kiffsta Senior Member

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    Nice work mate
     

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