Thread: XLT exhaust removal secret
03-12-2012, 08:00 AM #1
XLT exhaust removal secret
I'm trying to remove the exhaust to add d-plates to my skis.....What is the secret to getting the rear section of the exhaust out of an xlt1200? This is my second time getting in there and both times it has been a complete pain. The bracket under the cat that mounts it to the block will not clear the head. Last time we had to take the head off to get the exhaust out. I reached under the cat to try to break the bolts loose and remove the bracket....yeah that didnt work.
03-12-2012, 02:47 PM #2
U got it pull the head and behind the #3 jug remove that stinger brace also . Wonce u have those 2 parts off do a barrell role with it counter clockwise was u pull it out . Good luck and "god speed". Lol
03-12-2012, 07:35 PM #3
Remove the lower brace to the top case and pull the water box back. Of course clear out all wiring. Key to me is to pull up the top while moving the bottom away from the water box side and rotating it at the same time. Sounds weird, but wiggling helps.
03-12-2012, 08:36 PM #4
- Join Date
- Oct 2009
- Green Cove Springs Florida
i pull the vent tube out to get some more clearance also. No need to remove the head or cyl. pull and rotate. you'll get it after a few tries. I would place a thin towel or the like over the head and side of cyl just so you don't bang it or scratch it up too much. third try or so you'll be able to do it in a matter of mins.
03-13-2012, 04:38 PM #5
- Join Date
- Aug 2006
Like those above have said, its in the rotation. Remove the lower rear bracket and lift up/rotate. I cannot tell you the secret, because for me sometimes it almost falls out without a single problem, and other times it is a bear. I've done them 15-20 times and have not pinpointed exactly the trick.
03-13-2012, 05:05 PM #6
1. remove upper mount below cat
2. remove lower lord mount
3. remove or pull-back waterbox hose (very good recommendation)
4. lift and rotate
That's what I do, and when I rotate I do it from the right-side of craft and rotate it forward/left. Kinda like the 70's commercial, lift and separate
03-20-2012, 10:19 PM #7
Thanks guys. I completely removed the rear lower bracket and the intake vent tube. Plus i swore at it alot. I never did fully remove it. I just rotated it so i could get access to the bolt on the bottom for the CAT so i could add the D-plate. I think the trick is to just swear at it alot. haha
03-20-2012, 10:22 PM #8
yea wait until you are ready to go back in, its even more fun.
03-22-2012, 09:03 PM #9
03-23-2012, 07:55 AM #10
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