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  1. #1

    Can't get exhaust chamber out on XLT1200??

    I have a 2001 XLT1200 and I am trying to get my exhaust chamber out so I can work on the oil lines and replace the notorious clamps on the oil lines. I have removed the stinger (after a bit of a struggle), but now I'm struggling even more with the exhaust chamber.

    I have been following the instructions from cajundude and his excellent pictures, but I'm stuggling to get a socket to the 4th bolt in step 1 where you unbolt the exhaust chamber from the manifold. I have tried a universal joint, extensions, etc, but can't get to the bolt. The bolt is so close up against the fiberglass side of the waverunner, I can't get any wrench on it. How did they install this thing? Any tricks??

    Jason


  2. #2
    60% of the time, it works every time.
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    I used 1/4" drive ball joint swivle and extention. You should be able to get to it with a regular 1/4" swivle just be careful of it snaping on you. It is a very tight squeeze. Hope that helps.
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  3. #3
    Happily Self-Employed WFO's Avatar
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    even with a 14mm impact wiggle socket (#1 recommended for this bolt) its still a bitch... I usually pry the top of hull away from the U-pipe a bit

    long pry bar or thin pipe

    I know I know, but the hull wont break if you are careful and dont go too far

  4. #4
    60% of the time, it works every time.
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    haha, funny thing is, I was gonna suggest this but decided to keep it to myself as to not get bombarded with flack from the experts such as yourself Rich.

  5. #5

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    yep...3/8" drive short socket with a swivel will get it out.

  6. #6

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    done mine a few times & used 1/4" drive

  7. #7

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    Quote Originally Posted by WFO View Post
    even with a 14mm impact wiggle socket (#1 recommended for this bolt) its still a bitch... I usually pry the top of hull away from the U-pipe a bit

    long pry bar or thin pipe

    I know I know, but the hull wont break if you are careful and dont go too far

    Wish I read this before I did mine. I ended up loosing the motor mount bolts and twisting the engine. I have little problem with this bolt on a GP1200R, but the XL1200's bolt is a bitch as WFO said.

  8. #8
    dockwalker's Avatar
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    Your right, XL is a PIA.I used a wooden wedge to spring the side out a little and used a 3/8 swivel socket.

  9. #9
    elmatta's Avatar
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    I did the lazy mans way and loosened the cylinders and tilted the top end away from the hull. I had the cylinder head off anyway, so it wasn't too much work.

    If i kept my gp1200r, I would of endedu p cutting a notch in that location for easy access

  10. #10

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    What I have done all my own machines is using my die grinder cut a little groove up and down in the top bonding bead in the upper hull to allow the ratchet extension to have a bit more clearance. The hull is double wall there and thick, I go in probably just under 1/4" deep using a 3/8" cutter. Makes life a lot easier and causes no issues with strength or sealing. A little trick I also use is a wobble extension, plus a bit to tape from the extension to the socket to prevent loosing the socket deep under somewhere.

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