Just picked up an 06 rtx. Problems already - y pipe removal

[klitts]

Just bought my first Yamaha sled - 06 Apex rtx. After reading a lot on this sight, I decided to tear down to look at the exhaust donuts conditions. Turns out they are so bad, they are completely gone. And the left y pipe has a hole from the donut clamp wearing into it.

So, in trying to get the y pipes out, all 4 notorious rusty bolts were so rusted that they broke or stripped - even with heat. Anyway, now with the skid out and everything, I CANNOT get the y pipes to disconnetct from the rear muffler section. I tried everything I could think of including heat.

My next step is to cut the left one (with the hole) since I'm replacing it anyways. I think (hope) the rest will then have enough room to get it out.

Anyone have any other ideas? Or is this a pretty common situation?

 

[Yami_Nut]

I tore mine down last night to do the donuts after buying it a couple weekends ago, similar situation where the four bolts are rusty. I held off trying to loosen them, I'm going to go the drilling the rivets out route.

I'm lucky though the donuts are gone on two, no holes in the pipes. Good luck with swapping out the pipe!

 

[srxpert]

If you know for sure all the bolts are removed from the exhaust and the clamps are lose take a 2x4 and place it across the muffler and beat it with a big hammer. If you need more answers go back into the Apex section and look on top at the apex exhaust change sticky. Its all in there. Shane

 

[actionjack]

Since all the bolts are sheared off or stripped, cut the Silencer bands off and yank the muffler and rear pipe out. The bracket that the stripped Allen screws holding the y pipes to can be drilled out and dropped but won't come out whole with both pipes attached to it unless you cut out a heat exchanger. Since you're getting a new y pipe you can cut that or try to drill out one of the Allen screws holding the broken y pipe. I was only able to drill one of the Allen screws out and exhausted all my bits.

I hate those people who dig in to this and report back it only took them an hour and a half!

 

[NY AttakGT]

Re: Just picked up an 06 rtx. Problems already - y pipe rem

So, in trying to get the y pipes out, all 4 notorious rusty bolts were so rusted that they broke or stripped - even with heat. Anyway, now with the skid out and everything, I CANNOT get the y pipes to disconnect from the rear muffler section. I tried everything I could think of including heat.

Stupid question....but did you loosen the two 12mm bolts on the clamps that hold the exhaust to each of the Y pipes? You get access to the bolts by removing the rubber grommets along the top of the tunnel.

If so, these can be a bear to separate sometimes. I just helped a fellow TY'er pull his exhaust apart and it took no less that 50 or 60 good wacks with a rubber mallet on the rigid outer edges of the muffler, along with a whole lot of heave ho'ing to get it to come loose.

 

[klitts]

Re: Just picked up an 06 rtx. Problems already - y pipe rem

Stupid question....but did you loosen the two 12mm bolts on the clamps that hold the exhaust to each of the Y pipes? You get access to the bolts by removing the rubber grommets along the top of the tunnel.

If so, these can be a bear to separate sometimes. I just helped a fellow TY'er pull his exhaust apart and it took no less that 50 or 60 good wacks with a rubber mallet on the rigid outer edges of the muffler, along with a whole lot of heave ho'ing to get it to come loose.

Yes - they broke, which allows the bands to become loose. I was then able to take them right off.

I tried everything i could find on this sight - and then some. The small flanges on the muffler side are even slightly bent from hitting them so hard.

I did read a few posts where they had to be cut off, so I think I'm in the same boat. I've never seen this type of joint THIS tight!

 

[klitts]

Since all the bolts are sheared off or stripped, cut the Silencer bands off and yank the muffler and rear pipe out. The bracket that the stripped Allen screws holding the y pipes to can be drilled out and dropped but won't come out whole with both pipes attached to it unless you cut out a heat exchanger. Since you're getting a new y pipe you can cut that or try to drill out one of the Allen screws holding the broken y pipe. I was only able to drill one of the Allen screws out and exhausted all my bits.

I hate those people who dig in to this and report back it only took them an hour and a half!

I ended up drilling out both allens as well as all the rivets holding the bracket in, in hopes that it would all drop down to where I could work on it easier, but it didn't help much. I'm just hoping that cutting one y-pipe gives enough room to get the rest of the exhaust out with no issues. Once out, I can then work on the bench to get the cut piece out of the rear section.

 

[Budweiser]

Well, if it makes you feel better, I think its a bitch to do! Any bolts you put back use anti-seize. Will make it easier to take apart next time. Hardest part I always have is putting the exhaust back in. I always have a terrible time getting the muffler to slide into the Y-pipes. I also have the bracket drilled out and use SS bolts to reconnect. I'm assuming you stripped the Allen head bolts? I've done that and just bent the bracket to get everything out. Then I just bent it back together after getting the bolt out.

Good luck!

 

[snowbeast]

Since all the bolts are sheared off or stripped, cut the Silencer bands off and yank the muffler and rear pipe out. The bracket that the stripped Allen screws holding the y pipes to can be drilled out and dropped but won't come out whole with both pipes attached to it unless you cut out a heat exchanger. Since you're getting a new y pipe you can cut that or try to drill out one of the Allen screws holding the broken y pipe. I was only able to drill one of the Allen screws out and exhausted all my bits.

I hate those people who dig in to this and report back it only took them an hour and a half!

I ended up drilling out both allens as well as all the rivets holding the bracket in, in hopes that it would all drop down to where I could work on it easier, but it didn't help much. I'm just hoping that cutting one y-pipe gives enough room to get the rest of the exhaust out with no issues. Once out, I can then work on the bench to get the cut piece out of the rear section.

Hope all goes well,and you get the new donuts on,because this is by far one of the best apex sleds yammi made,we still have our 06 rtx,one sweet sled. You will have lots of smiles from this sled,once its up and running good. best of luck..

 

[kinger]

Yes the apex exhaust is truely a PITA to work on, I never swore so much I just swapped out my stock headers for some excel.

I too had a heck of a time getting the muffler off I ended up prying the tabs at the joint up a bit with a screw driver to loosen them and then yanked and banged it, to no avail. I then used a ratchet strap and went around the muffler and put pressure on it then started pulling and yanking and it finally came off.

On the install it was worse, when I bent the tabs of the exhaust clamps back it bent the exhaust pipe in slightly at the bottom of the tab and it made it nearly impossible to get back together, again I used a ratchet strap and grease on the fittings to get it back together.

On the Y pipe again a huge PITA with the hangers facing forward there is no way to remove it without either removing the flex pipes from the head of the motor or drilling out the 10 rivets that hold that bracket in, others are right though you still need to get the y pipes loose from that bracket because they wont come out as a pair only one at a time with the stud protectors in place.

I do have a spare set of stock headers in good shape if you need them from my 06 with about 4000 miles on them.

Good luck, lots of swearing helps! LOL

 

[actionjack]

Just to be clear. I did not remove the flex pipes from the block as I was afraid of F-ing that up. On my sled, the Y-pipe hanger Allen screws stripped. I was able to drill out the chaincase side which freed that Y-Pipe. The clutch side pipe was still attached to the bracket so I drilled out the 10 rivets holding the bracket. I was able to twist that bracket so the chaincase Y-pipe came out, then twist is so the bracket and cracked clutch side Y-pipe cleared the tunnel protectors and dropped out.

The part of this that was easy for me was the rear pipe and silencer broke free easy and literally "popped" into place when re-installing once I lined the pipes up.

Check for loose tunnel protectors and loose cooler crossover tube while the muffler is out.

The bracket I re-installed with SS bolts with nylocks
I replaced those damn Y-pipe hanger allen bolts with SS Hex heads.

By not removing the flex pipes putting it back together was a little tricky but done.

I used the updated factory donuts that come with a new screw because I was unaware of the copper ones at that time - plus I remain slightly skeptical about them.

 

[Budweiser]

That is exactly how mine is set up. Will be much easier to change them out next time! Although I can never get the pipes to "pop" in. Lot of swearing and bloody knuckles get them in for me!

 

[klitts]

Check for loose tunnel protectors and loose cooler crossover tube while the muffler is out.

Thanks for the tip. Will do.

Well the exhaust is out! WOW! Even with one y pipe cut off, it was still really tight getting the rest out, but got it.

Once out, on a bench, I wiggled and twisted the y pipes out of the rear section. As much work as it was, There was no way that was going to happen while still on the sled. The gasket sleeves in the joints were "fused" to the pipes.

The install HAS to go better than that! We'll see.

 

[Honk]

This sled may be new to you, but its been out since 05. Thats six seasons! Tearing it apart will give you GREAT info as to repairs, and knowing that you can do them. Just think about the money your savin, cause some people have to pay to do this job. Its only Time. Have fun! Glass is half full, its all how ya look at it, take it from there.

 

[klitts]

This sled may be new to you, but its been out since 05. Thats six seasons! Tearing it apart will give you GREAT info as to repairs, and knowing that you can do them. Just think about the money your savin, cause some people have to pay to do this job. Its only Time. Have fun! Glass is half full, its all how ya look at it, take it from there.

I totally agree. It's not so much the miles either (only 3700), it's the time that really kills - 6+ years, like you said.

I don't mind doing the work either. I like to know exactly what I have.

Just have to finish the exhaust, replace front suspension bushings, replace steering post bushings, change oil and filter, and change a couple bogey wheel bearings, and I'll be done!