Boxerworks.com

I like this post so much, I "immortalized" it as a JPG on my photo site.
Unfortunately, this new forum won't accomodate such a wide image. You will have to click on it to read it all:

I appreciate the continued great advice.

The lead mechanic at the independent shop has many years of experience as a BMW mechanic and previously was service manager at a BMW dealership.

His scheduled maintanance program does in fact include loosen the star nuts from the cylinders and reinstall the pipes
presumably with anti-seize compound. Unfortunately, when he first serviced my cycle he discovered that the procedure apparantly had not previously been done and after 24 years, the exhaust was firmly mated to the cylinders.

In any event, the cycle still has an original exhaust system, that seems to be in pretty good shape for being 26 years old.
I suppose that it is out of warranty Right?

You make good joke, John!

I have read other post-'80 R65ers cuss about trying to get the headers back together, what with both crossovers having to come together at the same time. And that's if you can get them apart, after 24 years. I don't know how the centerstand enters into it. But you have someone else handling those chores for you. So, you have a good job, eh?

Electrolux vacuum cleaner extension pipes make good, cheap stock for the crossovers, if you just want to cut the old ones apart. New ones are $80!!!
(Thanks Jean! I've never forgotten!)

Many thanks Rob.
If you like the x-over shiny, change them out every 3 or 4 years.
You use the fancy clamps over and over...Sometimes I get the pipes for free, sometimes they cost $2-$3.
I put instructions in the "Airmail" last year on how to do this.

One should really consider that the exhaust nuts are expendable. If (huge IF) they do come off easily, one is just lucky. If the threads on the head are buggered up, then the head has to come off. The head must be shipped off for repair and that bill will be $200, plus the labor. At that time, you may also find that it needs new valve guides etc. It is very easy to go over $1000 on this venture.

Just be sure that you have a mechanic that knows his biz.

Jean wrote: You use the fancy clamps over and over...

Oh yeah - I forgot to mention the T-Bolt Clamps!

http://www.jcwhitney.com/stainless-t-bo ... 15038.jcwx

http://www.partssystems.com/100-stainle ... lamps.html Another source of T-Bolt Clamps.