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SECTION F:

EXHAUST:

--Tools and Chemicals:



EXHAUST SYSTEM TOOLS:

NOTE: SOME OF THE FOLLOWING TOOLS ARE AVAILABLE FOR RENTAL!!: some tools are a one-time or infrequent use tool, so it may be more economical for you to rent them from us, rather than to purchase outright. Please see the “rental” section within the THE TOOLBOX section of our catalog at:

http://xjbikes.com/forums/index.php?threads/xj-parts-catalog-section-p-the-toolbox.44630

and review the availability and procedures in the TOOL RENTAL section.


Prevent any of the above situations from happening to you by using one of our anti-seize products when installing your new bolts!


it54) Aftermarket broken stud EXTRACTOR TOOL KIT. Common problem: you snap or shear off the head of a fastener, now what do you do? Prevent these situations from happening to you by using one of our anti-seize products when installing new bolts or studs!


HCP10302 Aftermarket 6mm BROKEN STUD EXTRACTOR......this is the correct size for both the exhaust headpipe studs and the intake manifold bolts in the cylinder head, which are the most common fasteners that you'll need to use these extractor tools on. You simply pound this extractor onto the stud, and then use an open-end wrench to twist it out. As long as you have a bit of the broken stud remaining outside of the cylinder head threaded hole (in other words, the fastener has not broken off "flush"), then this tool is what's going to save your day. Similar in concept to a "ez-out", but these tools have their "biting" surfaces on the inside of a socket-type housing, so that the hardened steel ridges bite into the stud and allow you to extract it. Also works great on screw or bolt heads that have had the drive slot ruined or the bolt head rounded off.
$ 69.95

HCP26979 Aftermarket complete STUD EXTRACTOR and INSTALLATION TOOLS SET. Complete set of 3 different size tools, these are an upgraded version of the “two locking nuts” method of stud extraction or installation, and their small size allows them to work easily in cramped spaces. Note that this type of tool requires that you have decent threads on the end of the stud: www.youtube.com/watch?v=NNH7u87dhng This set has the proper sized tools to install and remove exhaust manifold studs, cylinder head and cylinder jug studs, the long cylinder head-to-crankcase studs (all models except XJ700-X and XJ750-X engines), broken intake manifold bolts and many other threaded studs (or headless bolts) on the engine and drivetrain. Contains one each M6 x 1.00 pitch, M8 x 1.25 pitch, and a M10 x 1.25 pitch tool.
$ 29.95

HCP10301 Aftermarket complete STUD EXTRACTOR TOOLS SET. Complete set of 4 different size extractors, and these can be used with ratchet wrenches for ease of removal. These are “roller clutch” type removers that use internally locking rollers to grip and turn the stud. This type tool will damage the threads as part of the removal process, and although it’s possible to use them on broken threads (the smooth shank portion of the stud, even if that is all that is present i.e. the stud or bolt has snapped off and all that remains is the unthreaded portion), they don’t always work all that well on smooth surfaces…..but this also means that the can also be used on dowel pins and some guide collars. Note that these stud removers are much larger is physical size that the HCP26979 tools, which may present problems in restricted areas: www.youtube.com/watch?v=aE5VnScjRcI This set has the proper sized tools to remove exhaust manifold studs, broken intake manifold bolts, cylinder head and cylinder jug studs, the long cylinder head-to-crankcase studs (all models except XJ700-X and XJ750-X engines), and most other threaded studs (or headless bolts) on the engine and drivetrain. Contains one each of a 6mm and 8mm extractors (which can be used with 3/8" drive ratchets) and one each of a 10mm and 12mm extractors (which can be used with 1/2" drive ratchets). You simply pound the extractor onto the stud, and then use an appropriate sized ratchet wrench to twist it out. Comes in a molded storage case.
$ 79.95


Removing broken bolts and studs with the power of electricity:




Or, you can put the power of chemistry to work for you:

https://tap-die.com/contents/en-uk/d296_Tip_Remove_Broken_Tap_Drill_Reamer_Tap_and_Die_Co.html

Alum powder, get it at your local supermarket:

https://www.walmart.com/ip/McCormick-Alum-1-9-oz/10535117



HCP2399 THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For the following holes: all XJ550 - XJ900 models cylinder head exhaust port stud holes.
$ 12.95

HCP11028 THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For the following holes: all XJ1100 and XS1100 models cylinder head exhaust port stud holes and most collector inlet and outlet cinch clamp threaded holes. Any of the turbocharger threaded holes which are an M8 size will also use this size tap.
$ 12.95

HCP26760 THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For the following holes: all XJ and XS1100 models exhaust hanger bolt holes..
$ 17.95


HCP28170 Aftermarket thread tap or EZ-out extractor TAP HANDLE, featuring offset tap handles and fully adjustable head for all m3-m12 size taps and size 0 to ½” extractors. This is the proper way to hold a tap or extractor to insure that the force is directed straight down and doesn’t “wobble” as you are cutting, reaming, or extracting. Much better than using pliers or vise-grips to hold the tool……..
$ 17.95



NOTE: always use a proper thread-cutting oil or lubricant before using thread taps! Thin motor oils work fine when merely doing a "clean-up" thread chase; a real cutting fluid should be obtained if a threaded bore needs to be truly cut:

NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the Priority Mail level of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Therefore it may have to be shipped in a separate package from the remainder of your order, and will thus incur additional shipping charges.

HCP2402 Aftermarket machinist-grade professional THREAD CUTTING FLUID, for use when cutting into aluminum or other soft metal. 4-ounce non-aerosol can.
$ 8.95

HCP2403 Aftermarket machinist-grade professional THREAD CUTTING FLUID, for use when cutting into steel or other ferrous metals. 4-ounce non-aerosol can.
$ 8.95




EXHAUST SYSTEM CHEMICALS:

Assembly Chemicals:

xx1) Fastener ANTI-SEIZE PASTE. Yeah, it's smelly and makes a silvery mess on your fingers, but this stuff is a life-saver for any true wrencher, because it prevents problems down the road. Use it on any metal fastener that does not require a "loctite" thread-locker material to be used. This means on just about every fastener that is carb, engine case, or suspension-related! (except for carb upper and lower rack-mount screws and butterfly valve screws, which do require the use of a thread-lock fluid). If you think that it might, sometime, in the future, need to come off: use anti-seize compound! NOTE: the "base" metal material used in the different anti-seize pastes below do not determine what type of fastener to use such pastes on; it merely signifies what base material is used to create the anti-seize paste. You can use any "based" anti-seize paste on any type of fastener and metal.

NOTE: the use of anti-seize compounds will result in a TORQUE-MULTIPLYING EFFECT……..the result of a reduction in friction between the threaded contact points……and thus fasteners treated with anti-seize compound should have their torque values reduced by at least 10-15% when installed into steel material, and up to 25% into aluminum materials or other “soft” metals” (such as spark plugs into cylinder heads, or almost any other type of fastener into the engine) …… note that this rule applies only to service manual torque specifications on fasteners that are not indicated to be treated with anti-seize fluid by the factory …. if the factory manual specifies the use of an anti-seize coating, then the specified torque value for that fitting already takes into account the “reduced torque” necessary.

http://raskcycle.com/techtip/webdoc14.html

http://www.cncexpo.com/MetricBoltTorqueNm.aspx

http://www.bmwmotorcycletech.info/sparkplugs.htm

http://www.antiseize.com/pdf/torque_specifications.pdf


HCP1264 Aftermarket fastener ANTI-SEIZE PASTE, standard grade aluminum-based in a 1-ounce squeeze tube, for smaller jobs.
$ 5.95

HCP1265 Aftermarket fastener ANTI-SEIZE PASTE, standard grade aluminum-based formula in a 4-ounce tub with a brush-lid, for larger jobs.
$ 7.95

HCP9784 Aftermarket fastener ANTI-SEIZE PASTE, standard grade aluminum-based formula in an 8-ounce tub with a brush-lid, a lifetime supply for your motorcycle!
$ 12.95

HCP9763 Aftermarket fastener ANTI-SEIZE PASTE, standard-grade copper-based formula in an 8-ounce tub with a brush-lid, a lifetime supply for your motorcycle!
$ 12.95

HCP9764 Aftermarket fastener ANTI-SEIZE PASTE, premium-grade nickel-based formula in an 8-ounce tub with a brush-lid, a lifetime supply for your motorcycle!
$ 17.95


NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the Priority Mail level of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Therefore it may have to be shipped in a separate package from the remainder of your order, and will thus incur additional shipping charges.

HCP20860 Aftermarket industrial-strength ASSEMBLY LUBE, in a standard 12-ounce aerosol can. Heavy-duty formula includes graphite to not only enhance and speed up the penetrant action, but also gets down into the pores of the metal for the greatest possible lubrication possible. Won't wash away, protect against rust and corrosion, stable from 0-degrees up to 250-F. This fluid is also a great choice for use as a drive cable lubricant.
$ 21.95

HCP20862 Aftermarket super-duty ASSEMBLY LUBE, in a generous 10-ounce aerosol can. The cat's-meow of lubricants, infused with pure moly disulfide, it goes on wet and then dries in 1-2 hours to a super-slick, high-pressure, hi-temp, bearing-like finish which provides the ultimate level of protection. Prevents rust and corrosion, won't wash off, throw off, and won't attract dust or dirt. Surfaces must be clean and dry of previous oils, etc. before application. Can even be used as an engine, tranny, and drivetrain assembly lube!
$ 24.95

HCP20863 Aftermarket super-duty GRAPHITE LUBE, in a generous 10-ounce aerosol can. The 800-pound gorilla of lubricants, it's infused with pure graphite, goes on wet, and then dries in 10 minutes to a super-slick, high-pressure, bearing-like finish which provides the ultimate level of protection. Prevents rust, won't wash off, throw off, and won't attract dust or dirt. Surfaces must be clean and dry of previous oils, etc. before application. Can be used as an engine assembly lube, bearing or bushing pre-lube, great for lock cylinders, and all metallic sliding surfaces. Use where dusty or dirty conditions render oil-based lubricants ineffective or undesirable.
$ 21.95



Super-Penetrant Fluids and Lubricants:

Sometimes, the toughest part of working on a vehicle is battling the effects of time: seized fasteners, caused by rust, corrosion, and other factors, turns what should be a 5-minute effort into a 50-minute (or more) chore, complete with rounded-off, ruined, or snapped fasteners, e-z outs, heli-coil inserts, and more.........and that's just not right.

While the proper use of our various Anti-Seize products will prevent these nightmares from occurring in the future, you're stuck in the here-and-now, and the best way to handle these obstacles is to have the proper tools at the stand-by; and in the case of fastener seizure, the proper "tool" is a can or two of our SUPER PENETRATING LUBRICANTS at the ready; a couple of squirts, a little bit of time-----perhaps some heat for those really nasty situations----and you're on your way again, hopefully not too much worse for the experience.....

Great for use on all fasteners, fork tube cap bolts, intake and exhaust manifolds bolts, studs, and nuts, lock cylinder tumblers, or anywhere an un-cooperative fastener can be found. Can even be used to help un-seize frozen engines!

Be aware that these products are not your typical, garden-variety, run-of-the-mill "retail" type products; these are designed an used as industrial- and military-strength products, meaning they have special formulations that include a dollop more of the "good stuff" within them to solve the toughest seizure problems imaginable (the "good stuff" ingredients cost more, and it is those compounds that are left out of or reduced in concentration in "retail" level consumer products).

NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the Priority Mail level of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Therefore it may have to be shipped in a separate package from the remainder of your order, and will thus incur additional shipping charges.

HCP10331 Aftermarket standard-duty PENETRATING LUBRICANT, in a generous 16-ounce aerosol can. Oil-based lubricant penetrates down into spaces of one-millionth of an inch to handle the most reluctant seizures. Actually dissolves the rust and corrosion that causes the seizure; lubricates and displaces moisture to prevent rust re-formation. This product is what we use and recommend for freeing stuck fork tube cap bolts and other such challenging fasteners.
$ 24.95

HCP11974 Aftermarket super-duty PENETRATING LUBRICANT, in a generous 13-ounce aerosol can. Same as our standard-duty formula above, but also includes graphite to not only enhance and speed up the penetrant action, but also gets down into the pores of the metal for the greatest possible lubrication possible. The cat's-meow of penetrating fluids, can even be used to un-seize frozen engines or as an engine assembly lube! This fluid is also a great choice for use as a drive cable lubricant.
$ 26.95

HCP10333 Aftermarket extreme-duty PENETRATING LUBRICANT, in a generous 16-ounce aerosol can. Same as our standard-duty formula above, but also includes liquid silicone to enhance and speed up the penetrant action. This product is also an exceptional choice for use as a control-cable lubricant.
$ 27.95




Rust Removal and Prevention Fluids:

rr4) Concentrated RUST REMOVER magically dissolves rust on all iron-based metals. Spray or wipe directly onto rusty parts, or immerse the items in a container full of this solution (diluted), let it work, then rinse off. Highly concentrated, easy to use, leaves the metal surfaces grease-free and ready for further processing or finishing. GREAT FOR DE-RUSTING THE INSIDE OF GAS TANKS!

NOTE: the following product can only be shipped via ground transport (which thus eliminates the Priority Mail level of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Therefore it may have to be shipped in a separate package from the remainder of your order, and will thus incur additional shipping charges.

HCP12358 Aftermarket RUST DESTROYER FLUID, in a 16-ounce plastic bottle. Best to transfer into an old windex spray bottle (etc.) and use with a spray nozzle. After use, it is recommend that the de-rusted parts be immediately painted (or similar) or coated with fogging oil, lubricant, or other surface finish to prevent flash surface-rusting of the newly cleaned parts. Each:
$ 19.95


Here are a few other good ways to de-rust metal products:

- soak iron (steel) parts in heated vinegar (doesn’t matter what kind) overnight, then rinse with clean water. and finally spray with fogging oil (or similar) to prevent rust from re-forming.

http://www.mopedarmy.com/wiki/Removing_rust_from_a_gas_tank

http://users.eastlink.ca/~pspencer/nsaeta/electrolysis.html

http://www.moreg.org.au/dissolving_rust.htm

http://www.htpaa.org.au/article-electro.php

http://xjbikes.com/forums/index.php?threads/32838

http://xjbikes.com/forums/index.php...val-no-frills-easiest-fastest-cheapest.48196/

http://www.robertscycle.com/chrome-clean.html

http://www.xjbikes.com/forums/threads/teds-2nd-82-xj750-maxim-bobber-project.47929/#post-478002

http://www.practicalmachinist.com/vb/general-archive/rust-removal-using-molasses-90452/




HCP11475 Aftermarket aerosol FOGGING OIL, top end lubricant coats, clings, and protects metal surfaces against rust and prevents ring seizure when an extended period of non-use is expected (winter storage). Spray directly into cylinders (thru the spark plug holes), rotate the engine over a few turns with the starter motor (but with plugs still removed-----do not allow the engine to start!) to spread the oil about, and your pistons, cylinders, rings will live happily ever after...............or, at least until you start up the engine next spring! 10-ounce can will fog many a cylinder.
$ 9.95

HCP20866 Aftermarket industrial-strength RUST PREVENTION COATING, in a standard 10-ounce aerosol can. This protectant goes on clear and prevents rust from forming on all surfaces (including bare metal) for up to a year, even in an outdoor environment. Can be applied over painted surfaces, or easily removed with mineral spirits. Great way to protect "work in progress" type projects.
$ 18.95

HCP20867 Aftermarket industrial-strength RUST PREVENTION COATING, in a standard 10-ounce aerosol can. Heavy-duty formula goes on clear, and then dries to a wax-like finish, prevents rust from forming on all surfaces (including bare metal) for up to a year, even in humid or outdoor environments. Easily removed with mineral spirits. Great way to protect "work in progress" type projects.
$ 19.95



Leak Detection Fluid:

ld2) Concentrated LEAK DETECTOR FLUID reveals even the smallest of pressure leaks. Spray on the suspected areas......such as exhaust system joints, tire stems and valves, fork air system valves, etc.....and watch for the telltale mad rush of bubbles.

NOTE: the following product can only be shipped via ground transport (which thus eliminates the Priority Mail level of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Therefore it may have to be shipped in a separate package from the remainder of your order, and will thus incur additional shipping charges.

HCP12361 Aftermarket LEAK DETECTOR FLUID, in an 8-ounce non-aerosol bottle. Best to transfer into an old windex spray bottle (etc.) and use with a spray nozzle. Each:
$ 9.95
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