Guys, I'm sure this has happened to someone on here. I am doing maintenance on the gatortail and went to replace the muffler. However, I found the 12mm bolt heads to be corroded enough that the socket wrench and 30 star bit will not work. Have any of y'all run into this issue? If so, how did you get them out? I know it may seem like a dumb question, but i didn't want to screw anything up. Any advice appreciated. will try to attach a photo. Also I was able to take the two right ones out, but not without some elbow. The left side seems more worn. Is there a special type of socket wrench?

Vice grips..

Than replace bolts with new ones.

small pipe wrench will work if the heads get rounded off (will work now too).

Looks like a standard bolt head? Can't just use a socket?

Spray em with PB blaster and let em sit overnight before you try to turn em out will help. Tap a 6 point socket on it.

Then after you get it fixed start coating that thing down with corrosion x, it will help a lot.

Pb Blaster and tap with hammer several times. Let soak overnight. Tapping with hammer will help pb penetrate and vibrate some of the rust loose from the threads.

They make a easy out socket that worked great on mine. I seen a set the other day for around 20$. I now have 3/8 bolts in almost all my original bolt's on my dual.

Also once out change the gasket and go get you some good bolts with a good head. I went back with a hardened bolt that the head won't trip so easy. Don't put a pipe wrench on it as you come out it will waddle out the hole and could ruin the head

I always replace the stock bolts with SS metric allen head bolts whenever I replace a customer's motor.

Oh, the problems associated with exhaust bolts....

Try running the motor a little bit to put some heat to the engine - your block is aluminum, muffler and bolt are steel - aluminum expands faster than steel. Then strike the head of the bolt several times using a hammer and pin punch (flat ended) or - in your particular motor's case, even the torx (star) socket with an extension (and when I say strike, I mean beating it like you would a red-headed step child, not some pansie tap, tap). This impact tends to break loose the corrosion. Then try breaking the bolt loose using a 6 point socket or wrench - don't try the 12 point because you need the full surface area contact offered by the 6 point.

When putting it back together - save yourself ( or the next owner ) the problem you encountered by putting some anti-sieze compound on the threads of the bolts before you install them