Changing Donuts - Stripped the allen type bolts

[Bento]

I began the donut replacement following the directions found in the FAQ section. Everything was going great until I reached the point where I had to loosen the two allen type bolts near the front of the Y pipes. The rear bolts were simple but the allen type ones were very rusted and I stripped the heads. Is there any other way of getting the exhaust loose. I already have the flex pipes loosened from the motor. Just cant pull the flex pipes enough to get the old donuts out. Thanks

 

[ManhattanMike]

I had the same problem. I had to go to the hardware store and buy an extractor to get those bolts out in order to slide the exhaust back far enough.

Mike

 

[AttakDog]

Yeah those bolts are a pain for sure. I got mine out then put in new ones with anti-seize. I had to use heat to get the originals out. Make sure you also spread the muffler slip on tubes, I took out the gaskets and tapped them with a brass hammer. If you don't the muffler can be a bear to slip back on. Look for cracks in the muffler system too, mine were both cracked at the "Y"

 

[70superbee]

You can heat them up. But I used a dremel cutoff wheel and made a slot in them and used a craftsman screwdriver BIG ONE. With the hex shaft.
Lean down on it and turn it with a wrench. Then I got regular bolts and put antiseize on them. They are metric thread too.

Rich

 

[olsmann]

Yep same thing here, Had to get an easy out and then replaced them with actual bolts

 

[Bento]

Im gonna try the Dremel way. If that does'nt work I'm gonna weld a nut on the top and wrench them off. What a pain, this made my two hour job a two day job.

 

[KevinS]

I didn't strip them when I took mine out but I had to heat the crap out of them with a torch before they would break loose.

Kevin

 

[jds1000]

I began the donut replacement following the directions found in the FAQ section. Everything was going great until I reached the point where I had to loosen the two allen type bolts near the front of the Y pipes. The rear bolts were simple but the allen type ones were very rusted and I stripped the heads. Is there any other way of getting the exhaust loose. I already have the flex pipes loosened from the motor. Just cant pull the flex pipes enough to get the old donuts out. Thanks

I had the same problem and found a very easy solution. I drilled out the top of the allen bolts. They drilled very easy and I used a bit just big enough to take out the heads and not damage the threads on the Y pipes. Then I used one of those easy outs that go over a stud and removed the bolts from under the tunnel. This took Me about ten minutes to do and I couldn't believe how easy it was to do it this way.

 

[YamaBert]

Just a quick question for those that have replaced their exhaust donuts....One, has anyone not had this problem at all? Two, for those that have changed them, when can I expect them to go bad?....I got about 2400 miles on my 07 RTX and Im wondering if I should take a look at them while my sled is halfway ripped apart? Thanks, Mike

 

[NY AttakGT]

I would say yes...definitely take a look at them. I have an '07 Attak and at 2,300 miles two were bad, one was totally gone, and the other was ok. The one that was gone caused the clamp to rub through my Y pipe at the flange. Good thing it was all covered under YES.

Mine were just done towards the end of the season last year and I just checked them again while every was torn down.

--Steve (O.C.)

 

[black knight]

Bento if you come up with any new words while getting those bolts out let me know I've used all the good one in my foul vocab.
yamabert Had to change mine after first season at 3100mile.

Fluid Film lube, I swear by it, and when i have to use it.

best of luck

 

[kviper]

I have done a couple of these. What works really good with the Allen head bolt's that you get to through the tunnel is to take a torch and heat them up until cherry red then instantly cool with water, Do this two or three times if needed and they will come out with a proper sized wrench. By doing this it breaks up the rust from the expansion and contraction and also hardens the bolt's, Works much better than just heating. Hope this helps. kviper

 

[Bento]

Got them out by welding nuts on the top and they came out smooth. Put never seize on the new ones I installed. Thanks