Y pipe removal

[OneEyePolak]

What needs to be done to remove the y pipes from an Apex GT. I have everything tore down to replace the donuts from Rockerdan's step by step post (thank you very much Rockerdan) but found out I have cracks in my right y pipe and need to replace it. I am not sure of the correct procedure and could not find any other info with a search. If anyone could shed light on this for me it would be greatly appreciated.

 

[1CrazySledder]

Remove the seat, tank covers then the tank. I like to first slightly pull the tank back just a little. Then with a 10mm wrench, remove the one bolt holding the coolant overflow tank. Move it out of the way or remove from the sled completely.

Now that the small tank is out of the way, you can easly remove the hose clamp holding the fuel line just below and in between the coolant main tank and over flow tank. Then on the other side dissconnect the wire for the tank, then remove the line and wire connector from the fuel pump. Remove the tank.

Now, right under the steering linkage is a plate with 4 bolts. Tak a 10mm socket to remove those bolts. Turn the bars to one side and that plate will come out with minimal bending. There you will find the 4 clamps holding the headers ( Y-Pipe ) to the flex pipes. Allen head bolts hold these clamps.

Now, right under where the tank was, you will see 4 0r 5 little black plugs. Remove them and you will see the bolts that fasten the headers to the pipe and the header hanger. Remove these, then you can remove the rest of the exhaust.

Here's a link with some pictures.
http://www.ty4stroke.com/viewtopic.php? ... &start=105

The above is just off the top of my head, but is the just of it. Hope this helps you.

-1CS

 

[OneEyePolak]

I have all of that done and have removed the bolts that hold down the muffler but nothing seem to move. I was thinking that the skid had to be removed or something. My exhaust must be stuck or something if thats all there really is to do.

 

[stoutner]

Take all of the bolts out of the pipe and muffler along with the header bolts. It may take a bit of a grunt but you should be able to slide the muffler section apart from the Y pipe.

If you cant get at it very good, drop the back bolts out of the track/suspension and let the back half of the suspension hang down. You then should be able to seperate the muffler from the Y pipe.

Also, it is easier to disconnect/reconnect the fuel line at the right side fuel rail and leave it hooked up to the gas tank.

 

[berge75]

I have all of that done and have removed the bolts that hold down the muffler but nothing seem to move. I was thinking that the skid had to be removed or something. My exhaust must be stuck or something if thats all there really is to do.

When I pulled mine last week,I had a hard time getting the Y pipe- muffler joint apart. I soaked it with lube and just kept working it until it finally slid apart.

 

[ReX]

I agree. The y-pipe/muffler joint can be quite difficult to separate.

I found I had to leave the front connected (y-pipe to chassis and y-pipe to header) so I could leverage back and pull hard on the muffler. I also worked the muffler left/right/up/down to slowly separate the connection.

Once the muffler is out, the y-pipe should be fairly easy to remove (but I've never done it). You do need to remove the headers so the y-pipe can move forwards at this point.

Although you theoretically don't need to remove the skid to pull apart the exhaust, I'm not sure how to re/re the y-pipe with the track up against the tunnel. I suspect you will need to unbolt at least the back two skid/tunnel bolts and drop the back of the skid down so you can reach up to the y-pipes. It might be easier, at least for the first time doing it, to remove the skid completely so you can see exactly what is going on.

Good luck and let us know if you needed to remove the skid (I'd like to know for when I need to do my y-pipes...)

 

[SharkAttak]

are all these parts back ordered?

 

[OneEyePolak]

I have not heard if the parts are backordered yet but the good news is that Yamaha is going to warranty my my y-pipes, donuts and exhaust gaskets. I believe that haveing a good dealer going to bat for you is the best way to get any issue with Yahama resolved. My sled is 2 years out of warranty and have had a few issues that would have been very costly to me and Yamaha has covered them all. This all starts with a good dealer.