Problems removing stock exhaust on a C800B 2016

Hi Guys, I've got the black exhausts on this and the paint has been rubbish. I have been touching it up with VHT FlameProof ceramic paint up till now and the results have been very good. However, the time has come to remove the exhaust and get to to those bits you don't normally see, and I have hit a bit of a problem. Following the manual, the top muffler should be removed first. Having removed the two bolts holding th top exhaust to the bracket and slackening off the clamp bolt at the narrow end of the cone, by the O2 sensor, I was expecting to slide the muffler off. But it won't move to the rear, though it does move slightly up and down. Is it just sealed with heat and rust, or have I missed something. I can't undo the clamp at the large end of the cone, and it is in danger of twisting the clamp and breaking it, so I've got that soaking in penetrating oil.
The alternative approach is to remove the complete exhaust as one, but the two bolt heads that hold the bottom muffler are inaccessible with the top muffler in place (which is probably why the book says to remove the top muffler first!). The two nuts behind the bracket are difficult to access but I am soaking them in penetrating oil in the hope of being able to turn them without having to hold the bolt heads.
Any advice would be welcome!

OK Guys, it's off! In the end it was not too bad. The 2 nuts at the back of the exhaust bracket loosened up quite easily. One came right off but the bolt started turning on the other one but could be easily held with finger pressure. The rear exhaust port was easy to slacken off but the front one was a bit awkward. Because they have used Allen head bolts I had to cut down an allen key to get at the one on the left as it was inside the bend of the pipe. Had to remove the air filter, though, as it got in the way of the leverage on the key. As that worked quite well I used it for the othe bolt. I was going to have to move the crashbars forward a bit to get a straight run at it but the cut down allen key worked a treat.
  I'm glad I persevered with it because there was next to no paint left on the underside of the pipes. No corrosion, though, which was pleasing. I am thinking of replacing the front head bolts with hex head bolts to make it a bit easier next time. Not sure whether to use HTS bolts or stainless. The jury's out on putting stainless into an ally head so I will have a think about that. Two schools of thought on the use of copper grease on the exhaust port bolts as well.....decisions, decisions. I will replace the bracket bolts with stainless, though, as they are a bit of a mess.
  In the process of gathering information about the problem several people mentioned how heavy the complete pipe was so I put an elaborate support underneath it to take the weight. I don't know what these people call heavy but it was only half the weight of the exhaust on my old Honda 750 Aero!
  Got new crush gaskets arriving tomorrow from Fowlers via DPD. Local dealership hadn't got any and said about 10 days to get them! What a joke.
  I shall use up the rest of my £10 can of VHT FlameProof paint this time but I will consider having them properly ceramic coated if they have to be done again. I'd be interested to hear from anyone who has had this process done. There is a place in the midlands somewhere that does it but the name escapes me at the moment.

I have the same bike and I’ve misplaced my manual, could you tell me please if these exhausts are catalytic converted. Cheers Steve 03580

I can't find any reference to catalytic converters but I believe they have been fitted to the c800 since 2009.

KeithW wrote:

  I'd be interested to hear from anyone who has had this process done. There is a place in the midlands somewhere that does it but the name escapes me at the moment.

I'm pretty sure Dave (Katsd) had his exhaust ceramic coated Keith and he lives in the middle bit of the country too I believe 

Just did a bit of digging now  and   ....... ta da!!  https://www.suzuki800.com/t4922-ceramic-exhaust-coating?highlight=ceramic+exhaust

Thanks very much for the research. I missed that. As it happens I have been talking to to Zircotec in the event of needing a back up plan (which is looking like a shrewd move!). The Endurance range is still listed and I would go with the solid matt black. However, whereas it was £168 + vat in 2015, it is now £566 + vat!! Thinking about it as there are other options.

KeithW wrote:

However, whereas it was £168 + vat in 2015, it is now £566 + vat!! Thinking about it as there are other options.

     ......... Now that's what you call a price hike!!! 

Looking at Performance 1 Coating's Volcano range, in black, which is £275 + vat. They are part of Zircotec and are based at the same address. My home spraying wasn't as good as I had hoped!

I have got the exhaust back on with all the bolts loosely done up but it wasn't easy.I have changed the bolts that go through the bracket to allen head bolts and used a stainless washer under the head. Much easier to get the bolts between the pipes plus I can use a ball end allen key to hold the bolt while the nut is being tightened. I still had to remove the allen bolts holding the pipes together in order to get both bracket bolts through. What a game. I suspect that the fixing didn't change when when they introduced the fatter mufflers in 2009.

Thanks for that answer Keith re the catalytic question 03580 Steve

Well, my paint didn't last as long as I would have liked! Prep work not good enough I suppose. So, the exhaust came off again, much easier this time. Same dilemma though, whether to repaint it or get it done professionally. Squealing wallet won again! I did remove the sensors this time while considering the Zircotec solution. Rear one came out easily but the front one was difficult. Managed to get it out in one piece but the thread on the sensor was damaged. It's gone back OK but I've used high temp copper antiseize grease on the threads. All went back OK and it sounds OK.

 Decided to replace the 4 manifold bolts this time, as they looked a bit worn! I was just going to get some 8mm Allen bolts and use some nickel antisieze grease on the threads but I had a look at getting proper Suzuki bolts. I managed to get a pack of 8 for £5 but they have some orange coloured stuff in the end 7 threads. Anyone know what this is? If it is nickel antiseize that will be OK.  If it is thread locker or, worse still, copper antiseize I will revert to my original plan.

These new bolts that have arrived look like stainless steel and I was under the impression that stainless bolts shouldn't be used in an ally manifold. Is that right? These bolts are listed for most of Suzuki's motorcycles.