Removing exhaust?

[actionjack]

Need to remove exhaust to replace y-pipe - Find it tough to remove allen screws under grommets rear of donuts. Is this the only place the exhaust is mounted to the tunnel? If I remove the 4 bolts of the muffler and drill out these rivets, will the exhaust slide out the rear of the tunnel so I can attack it outside the tunnel?

 

[APEX 06]

Did you undo the mid pipe.

 

[actionjack]

I have the flanges off of the flex pipes and the 4 bolts off of the silencer. I haven't been able to budge either allen bolt or nuts under the rearward grommet - ran out of butane for my little torch. From reading Donut threads I was thinking if I just pulled it all out from behind the flex pipes it would be easier to the the exhaust apart and get the seized fasteners out.

I also read that at least one member left his y-pipes disconnected from the tunnel to let the tunnel flex without torquing the pipes as much - wonder how that has held up?

 

[Kaz]

To remove the Y-pipes I removed the muffler first - 4 bolts holding the muffler to the rear of the tunnel and you have to loosen off the center section clamp & slide muffler out to rear.

To remove the Y-pipes you have to remove the two allen head bolts holding up the front of the pipes and the donut clamps. Those allen head bolts have given some fits to loosen and remove. Try heating red hot and PB Blaster. If all else fails you can drill out the rivets holding the bracket and Y-pipe.

If you end up drilling out the rivets I suggest you bolt the Y-pipe support bracket in with SS screws and nylon lock nuts.

Also; there are a few posts all ready on this job, just do a search.

Kaz

 

[raginyamaha]

drill out the rivets for the mounting plate on the tunnel and remove them off the sled. had to do this for 2 others i did. Then put regular hex stainless bolts back in with a lot of anti seize.

 

[actionjack]

F me. Both allen bolts are stripped now. Broke off bolt on chaincase side mid pipe clamp. Got clutch side off. Drilled out the rivets for the bracket (6??) but not much movement. Guess I'm gonna have to drop the skid and start cutting from underneath.

 

[actionjack]

Broken bolt freed the rear pipe and silencer. That is out - new clamp needed. Y-pipes still comfortable in the tunnel.

 

[sledneck22]

http://www.ty4stroke.com/viewtopic.php?t=52520
This is a sticky for this procedure. There is a good right up and maybe ideas for removing what you speak of.
Dropping the skid helps a lot. Especially when removing the y-pipes.

 

[bigdog_mike]

bolt removal

had similar problems, stripped out allen bolts head and then drillout the head, then with the skid frame dropped down i was able to use vise grips to remove the remainder of the threads, then replaced with SS allen bolt and antiseize compound so it will be much easier in future, note, if you want the best result go with copper donuts, they will never go bad as the factory donuts do.

 

[actionjack]

This project has been kicking my azz but is fun too. Swing arms need to be half baked anyway so the skid came out and apart last night. Before that, I got the muffler out. I'll need a new mid clamp because even with it out of the sled I can not remove the end of the sheared off bolt. Now that the skid is out I can see the last bracket rivets so the y-pipes are soon coming out. I had bought a lot of the parts in the spring, including new Allen bolts for the y-pipes since I read that many stripped them out. I am now going to replace them with hex heads. I am also going to bolt the y-pipe bracket and tighten up the tunnel protectors and coolant crossover tube. I already have the "improved" factory donuts on hand. I have learned so much taking the sled apart.

A huge thank you to all the members who give tech info and post DIY threads. When I give up snowmobiling I'll be able to afford more tools to make these things easier!