Exhaust Donut Problem

[Pureadrenaline]

I need a little help...

I have the seat and tank off and am trying to take the bolts out of the exhaust under the rubber grommets, I got one of the bolts out, snapped the head off the other and both the allen bolts are so rusted that the second I touched them the head was stripped. If I try to drill the allens out is there anything under them I should worry about or are they in a spot that wont hurt anything. Also since I have one of the bolts out and the head gone on the other shouldn't I be able to pull the rear section of the exhaust out?

Thanks a lot,
pure

 

[sherlock29]

welcome to the infamous exhaust donut change...

drill out allen head bolts..if you can... if not... nothing real close under them... i'd try to take a small zip disk and maybe cut the heads off... or grind out to get them out.. once out you should be able to put some heat on them to to finish.. back 2 bolts are for the centre bolts... once these are loose the entire rear exhaust comes out leaving Y pipes...

if your this far in... you need to take tank off.. heat sheild... ect. to get to the donut clamps. or maybe your there...


good luck

 

[APEX 06]

welcome to the infamous exhaust donut change...

drill out allen head bolts..if you can... if not... nothing real close under them... i'd try to take a small zip disk and maybe cut the heads off... or grind out to get them out.. once out you should be able to put some heat on them to to finish.. back 2 bolts are for the centre bolts... once these are loose the entire rear exhaust comes out leaving Y pipes...

if your this far in... you need to take tank off.. heat sheild... ect. to get to the donut clamps. or maybe your there...


good luck

Yap cut them off.

 

[Pureadrenaline]

Yeah I already have the tank and heat shield off, can I check the donuts with the flex pipes still on? I'm doing this as a precaution since the sled still only has a little over 2,000 miles, I just like to know I'm not going to have any surprises during the season.

Is there anything else I should be checking while I'm doing this? I greased the bearings and everything before last season(500 miles) and plan on greasing the suspension again before this season.


Thanks!
pure

 

[turbine man]

bearings

Grease the jack shaft bearing behind the driven clutch.

 

[langow]

Yeah I already have the tank and heat shield off, can I check the donuts with the flex pipes still on? I'm doing this as a precaution since the sled still only has a little over 2,000 miles, I just like to know I'm not going to have any surprises during the season.

Is there anything else I should be checking while I'm doing this? I greased the bearings and everything before last season(500 miles) and plan on greasing the suspension again before this season.


Thanks!
pure

You can probably inspect the donuts to some degree with the flex pipes still on, but I think replacing them will be difficult, if not impossible without removal.

 

[Pureadrenaline]

How many bolts hold the rear part of the exhaust on? Right now I have the four bolts holding the muffler to the tunnel out and the two bolts threw the holes in the tunnel under the grommets out. I tried to give the muffler a good tug from the back but it doesn't budge, am I missing something?

pure

 

[snowbiscuit]

to remove muffler

The y-pipes are clamped to the muffler( remove grommet to get at). Your best bet is to remove suspension and get back end up to get at y-pipes from underneath. If it were me I would replace the y-pipes with stainless replacemant, the titanium will eventually break and if like me lost a month of riding with pipes on backorder.

 

[Ding]

for those who haven't stripped the heads yet . . .

Heat and forged allen sockets do the trick.

Apply the heat first and don't strip the heads. The forged allen socket doesn't strip the heads as bad as a standard allen wrench.

 

[sherlock29]

How many bolts hold the rear part of the exhaust on? Right now I have the four bolts holding the muffler to the tunnel out and the two bolts threw the holes in the tunnel under the grommets out. I tried to give the muffler a good tug from the back but it doesn't budge, am I missing something?

there are 4 bolts in the back. the heat sheild has to come off, the take the rest out. middle of sled has the 2 gromets for the centre bolts. unloosen them and give a big tug back. between the flanges of exhaust/y pipe here are 2 gaskets that slide over y-pipe/exhaust pipe.. they can be sticky... but a little wiggling and pull it comes right off. depending on year there is a bolt that holds centre of y-pipe this needs to be loosened as well. once all this... now comes the fun part of the donut clamps....

hope this helps.

 

[sledneck22]

I snapped all but one of the bolts on the upper part of the y-pipes that bolt up to the heat shield. I drilled all of them out. I now have my y-pipes free floating between the flex pipes and rear muffler. I put on almost 3000 miles last winter and when I checked them about a month ago they looked new still. I suppose being able to move a little prevents them from cracking and wearing the donuts as bad. I did however grind down my exhaust clamps from the flex pipes to the y-pipes so they were tight. This has worked well for me so far. More info here: http://www.ty4stroke.com/viewtopic.php?t=52520

 

[Pureadrenaline]

How many bolts hold the rear part of the exhaust on? Right now I have the four bolts holding the muffler to the tunnel out and the two bolts threw the holes in the tunnel under the grommets out. I tried to give the muffler a good tug from the back but it doesn't budge, am I missing something?

there are 4 bolts in the back. the heat sheild has to come off, the take the rest out. middle of sled has the 2 gromets for the centre bolts. unloosen them and give a big tug back. between the flanges of exhaust/y pipe here are 2 gaskets that slide over y-pipe/exhaust pipe.. they can be sticky... but a little wiggling and pull it comes right off. depending on year there is a bolt that holds centre of y-pipe this needs to be loosened as well. once all this... now comes the fun part of the donut clamps....

hope this helps.

Thanks this is exactly what I was wondering, I guess I just have to give it a better tug(tried and even was pulling the sled backward).

pure

 

[Honk]

Heat First!! comes off like butta