Page 1 of 2 1 2 LastLast
Results 1 to 10 of 14
  1. #1
    Diznasty's Avatar
    Join Date
    Jul 2011
    Location
    ERIE-sistable
    Posts
    140

    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.


  2. #2
    jlfx car audio's Avatar
    Join Date
    Jul 2011
    Location
    jackson, TN
    Posts
    534
    +1
    26
    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

  3. #3
    leejax01's Avatar
    Join Date
    Apr 2011
    Location
    Jacksonville
    Posts
    1,161
    +1
    98
    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.

  4. #4
    60% of the time, it works every time.
    Join Date
    Oct 2009
    Location
    Green Cove Springs Florida
    Posts
    508
    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.

  5. #5

    Join Date
    Aug 2006
    Location
    Indiana
    Posts
    1,274
    +1
    81
    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.

  6. #6
    Quote Originally Posted by LT1GMC View Post
    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.
    LOL, true that! I agree the main things are:

    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

  7. #7
    Diznasty's Avatar
    Join Date
    Jul 2011
    Location
    ERIE-sistable
    Posts
    140
    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

  8. #8
    crashhard's Avatar
    Join Date
    Jul 2007
    Location
    Philly PA, Wildwood NJ, Indialantic FL
    Posts
    2,382
    +1
    24
    yea wait until you are ready to go back in, its even more fun.

  9. #9
    "Hustler" Inkaddict's Avatar
    Join Date
    Aug 2007
    Location
    NJ
    Posts
    4,712
    +1
    26
    Quote Originally Posted by crashhard View Post
    yea wait until you are ready to go back in, its even more fun.
    +1 I hate working on those ski's

  10. #10
    Diznasty's Avatar
    Join Date
    Jul 2011
    Location
    ERIE-sistable
    Posts
    140
    Quote Originally Posted by Inkaddict View Post
    +1 I hate working on those ski's

    Ha no kidding guys. I learned that during my last rebuild. I just rotated it 90 degrees and braced it will towels so i could wrench on that lower bolt and get it out. whats the saying, "15lbs of sh!t in a 5lb bag"

Page 1 of 2 1 2 LastLast

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Similar Threads

  1. New Gasket Needed? GP1300R exhaust removal
    By Mike's GPR in forum Yamaha PWC Performance (2-stroke)
    Replies: 8
    Last Post: 10-31-2008, 02:22 PM
  2. xlt exhaust mod question
    By daeths in forum Yamaha PWC Performance (2-stroke)
    Replies: 14
    Last Post: 07-21-2008, 04:57 AM
  3. GPR/XLT Exhaust manifold nipple
    By mrbtd in forum Yamaha PWC Performance (2-stroke)
    Replies: 4
    Last Post: 10-03-2007, 06:31 AM
  4. XLT engine removal help!!
    By BlitzK in forum Yamaha PWC Performance (2-stroke)
    Replies: 9
    Last Post: 07-18-2007, 09:05 PM
  5. 99 xlt pump removal
    By hammerdog57 in forum Yamaha PWC Performance (2-stroke)
    Replies: 7
    Last Post: 01-10-2007, 09:17 AM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •