Exhaust Donuts

[09nytro24]

Well that's that, bolts that hold the y pipe to the tunnel are stripped, now what? Can't cut them off, because they are indented inside the tunnel, drill them out? But then how am I able to bolt the damn things back together? What a joke, good job yamaha, great design.

 

[schmidtty]

drill them out that is what I did

 

[09nytro24]

How without damaging the threads?

 

[09nytro24]

Do I have to worry about drilling a hole in my header pipe if I drill these bolts out? I have so far broken 2 bits, and I am having a very rough time even being able to drill into these bolts, the must be hardened steel.

 

[Apex2006]

Do I have to worry about drilling a hole in my header pipe if I drill these bolts out? I have so far broken 2 bits, and I am having a very rough time even being able to drill into these bolts, the must be hardened steel.

No, the clamp where the two holes line up go between the header pipes. I will post a pic from my son's sled in a moment since his is apart replacing the donuts............

 

[Apex2006]

Here is a pic from my sons sled where the header is out sitting on top of the tunnel. You can see the holes go between the header pipes. You will have to drill out the studs by starting small and you may collapse the screw as you dril larger. Otherwise drill out and re-tap. I know it sucks right now but it really isn't bad if you have the right bit that drills through steel. Let me know if you need any other pics since my son's sled is apart waiting for manifold gasket to arrive.....

 

[09nytro24]

Thanks, I just went and bought some good drill bits, hopefully I can get it. The nut appears to be welded onto the bracket, correct?

Also, why did you take off the flex pipe?

Of course the dealer didn't have any donuts in stock...debating on ordering the copper ones from sledtoyz

 

[Apex2006]

My son wanted to inspect the flex pipes as well since his donuts were completely gone. Flex pipes were fine but want new manifold gaskets since we took them off. Copper is the way to go unless you can get stock over the counter to get up and running today, but they will need to be replaced in another 1500 to 2000 miles. Copper last way longer but you need to order them.

 

[Apex2006]

Yes, the nuts are welded... Ouch!

 

[09nytro24]

Wtf kind of bolts are these...smokes 3 brand new carbide bits and neither one of them are out yet...this is rediculous

 

[birdmayon]

Make sure when you're drilling steel to go slow and use lube. That may be why you're smoking bits?

 

[09nytro24]

This is absolutely rediculous, now what is the trick to get the damn y pipe out?

 

[sorenson1610]

I've only followed this for a bit but what are you drilling out? Don't need to to remove the the header. I removed the individual flex joints when I did mine

 

[09nytro24]

Yea I didn't do that...and now the y pipe won't come out...I thought the bracket on the y pipe was the portion that had the welded nut, but it appear to be a separate portion, which will just make this suck even more.

Is there a trick to getting this y pipe out? It looks like its sort of locked in there by the bracket riveted to the tunnel.

 

[ALuCsRED]

Yea I didn't do that...and now the y pipe won't come out...I thought the bracket on the y pipe was the portion that had the welded nut, but it appear to be a separate portion, which will just make this suck even more.

Is there a trick to getting this y pipe out? It looks like its sort of locked in there by the bracket riveted to the tunnel.

The y-pipe has to slide forward before it'll drop down from the bracket. The bracket underneath has fingers that hold the manifold up, and the fingers are pointed towards the engine. Hopefully that makes sense.