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  1. #1

    2000 polaris 1200 exhaust manifold removal

    Is there a recommended method of removal? It sure looks like a nightmare. The bolts on the exhaust pipe on top of the manifold will hit the body of the ski. I am trying to eventualy remove the engine. Thank Don


  2. #2
    SXTERRA55's Avatar
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    Hey hows it going, I just helped my cousin do this on his slx cause his starter crapped out. It is kind of a PITA we ended up using the shortest 3/4 socket i could find on one of top bolts towards the outside of the ski and i ended up using an open ended wrench on the other, and you cant really take those bolts out till you move the pipe around a bit away from the hull. and your gonna have to take water box out too so you have the room to slide it back and up. hope this helps a little, i wasnt too bad theres just a lot of bolts holding the pipe and manifold on

  3. #3
    Quote Originally Posted by SXTERRA55 View Post
    Hey hows it going, I just helped my cousin do this on his slx cause his starter crapped out. It is kind of a PITA we ended up using the shortest 3/4 socket i could find on one of top bolts towards the outside of the ski and i ended up using an open ended wrench on the other, and you cant really take those bolts out till you move the pipe around a bit away from the hull. and your gonna have to take water box out too so you have the room to slide it back and up. hope this helps a little, i wasnt too bad theres just a lot of bolts holding the pipe and manifold on
    Thanks Did you pull the cars off also

  4. #4
    meant intake manifold when taking out the engine

  5. #5
    Polarisitis loonatik's Avatar
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    This 1200 removal instruction may help:
    http://www.shopsbt.com/pdfs/p1200.pdf

  6. #6
    SXTERRA55's Avatar
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    were just doing the starter for now but with the limited space in that hull i couldnt see any harm in taking off the carbs and exhaust header to give you more wiggle room

  7. #7

    The 1200 must be different that the 1050

    Quote Originally Posted by loonatik View Post
    This 1200 removal instruction may help:
    http://www.shopsbt.com/pdfs/p1200.pdf
    from your link because your instructions only mentioned that the exhaust pipe bolts going into the ex. manifold have 2 bolts on the top. This engine as 4. 2 of which are burried in the back with no possibility of getting a socket on it
    don

  8. #8
    Polarisitis loonatik's Avatar
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    I have 1200 and 1050, they're both about the same.
    Socket is great but sometimes doesn't do well in tight space. Offset box wrench is what I used for removing the (2) mentioned bolts.
    http://www.harborfreight.com/8-piece...set-32042.html

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