Exhaust Donuts & Y Pipes....Step by step

[ROCKERDAN]

Well i wanted to wait till the snow came back till i put sled back together....simply cause i KNEW if i was ready earlier,it would probably NEVER snow!..lol....

last night we got blasted with snow and coming down like a bastard still....so its time to ride again!....

Took some pics when putting the Flexpipes,and new donuts all back together....so basically you reverse the original step by step in my first post....here are some pics of what i did.

I felt it was premature how my donuts wore out in less then 4000 miles....so my theory is to surround them with a thin layer of ULTRA COPPER SILICONE....I feel this MIGHT help reduce the wear and tear....lets hope so!

GO DOWN TO NEXT POST THEN COME BACK TO THIS POST,as i couldnt fit all the pics into this post...

Dan

 

[ROCKERDAN]

Ok i had to do another post here as i had too many pics i think....here are the rest.....

anyone installing new DONUTS start at this post...then go up to prior post with the rest of the pics....or maybe a MODerator can move this back up.


Dan

START HERE:

 

[welterracer]

did you , or do you have to , add lock tight to the bolts holding the donuts in??

 

[stoutner]

Welter,

That ticking is how mine started out. Then later came the backfiring and once that happened it had no low end power compared to a stock machine. I finally got around to changing it and had already burned a hole through my Y pipe at the flange where the donut gasket is supposed to be. Also, my flex pipe was broken and leaking.

Parts are really expensive so I wouldn't wait too long. Maybe you can get through winter but I would do it in the summer for sure.

I had about 2000 miles on my sled when it started ticking and about 2500 on it when it started backfiring.

I didn't add locktite but maybe I should have...we'll see.

 

[ROCKERDAN]

NO locktite needed on any of these bolts in this entire job....I actually OILED all the exhaust clamp bolts and Y pipe bolts,you will see when you take it apart that these were VERY RUSTY due to heat of exhaust.

the flexpipe bolts going into head i DID NOT add any oil...just dry torqued to 16lbs.

I also forgot to say,that you should allow 12 hrs at least after installing SILICONE,so it can setup nicely.

dan

 

[Apex18]

good post, this should be a "sticky"

 

[welterracer]

My dealer ordered my donuts tonight.. he is going to cover them under the YES program..

I will do the install , just because i am very anal about my sled..

 

[ROCKERDAN]

that is good to hear.....i never did buy the YES warrantee....but if i keep this sled long enough it would be worth it!...so far i havent spent much on things.

keep us posted.

dan

 

[ReX]

Dan, did you make sure the clamps were going to be tight before you RTV'd everything?

In my case with the new donuts the clamps were still very loose until I ground down the clamp spacers by quite a bit.

I suspect for those of us with worn clamps and pipes that if you don't tighten up the clamps by grinding down the spacer the RTV will blow out quickly.

It sounds like yours were only "just" starting to go so they would probably still be fairly tight.

 

[favarcat]

I had to grind off alot on mine. They would just spin around without grinding them. I'm ordering new clamps to go along with the new y-pipe, but those are back-ordered also.

 

[ROCKERDAN]

Dan, did you make sure the clamps were going to be tight before you RTV'd everything?

In my case with the new donuts the clamps were still very loose until I ground down the clamp spacers by quite a bit.

I suspect for those of us with worn clamps and pipes that if you don't tighten up the clamps by grinding down the spacer the RTV will blow out quickly.

It sounds like yours were only "just" starting to go so they would probably still be fairly tight.

When i took mine apart,only one was turned down slightly,and they all felt good and snug....

Im not sure how they could be loose with new donuts....i cant see them wearing to the point where they would be loose with new donuts....but i gues it is possible.....

Im sure some of the rtv will end up coming off,but it will stay on alot better then the old 2 strokes which had no clamp around them at all...just ball/socket and springs....I like the way it all went together with the RTV,and since we already know how short they last without RTV,i felt this can only be better then stock.

always dozens of ways to skin a cat!...lol
Dan

 

[ArchSledder]

Y pipe

Just came back from a trip. I have an 06 Apex ER with 5,000 miles. Pulled up to a stop sign, it started backfiring. Tore it apart, found exhaust leak.

Looking for Y-pipes, mine on the right side has a hole in it about the size of a quarter. Does anybody have a clue where we can find this part which is on backorder from Yamaha?

Please call Bob 314-750-5760. Thanks!!!

 

[favarcat]

Re: Y pipe

A guy here with user name LANEO had a left one when I asked him. I didn't ask for a right one, he may have one. PM him to find out.

 

[welterracer]

Re: Y pipe

Where do you get the holes?? where the donut was and now wore threw??

 

[ReX]

Re: Y pipe

One of my buddies sleds needs a y-pipe too. His is also far too bad to ride and he's been on the phone with Yamaha, trying to find the pipes.

His sled has been out of service and at the dealer since late December. Friday he was told the earliest his sled will be up and running is the 3rd week of February due to the backorder.

His solution is he just bought a REV-XP and says he's done with Yamaha. He's installing the studs and windshield right now as I type this. Tomorrow I'll be riding with 3 REV-XPs, instead of with 2 Apex ERs and a REV (they've all turned to Skidoo).

I'm just hoping mine holds together. Considering how much material needed to be removed from the clamp spacers to tighten up on the new donuts, there can't be much left to my pipes either.

This isn't looking good for Yamaha...

If I was Yamaha I'd consider making up a whole bunch of flared short pipe sections that could be slipped over the ends of all the broken y-pipes and clamped in place. Maybe if it was made out of a slightly thicker gauge stainless steel, instead of titanium, it would last.