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  1. #1

    How to remove SL 780 Cylinder without pulling engine

    Has anyone sucessfully pulled the exhaust manifold and cylinders without pulling engine. I can't even get the expansion pipe out. No clearance between engine and top of fiberglass opening under seat.

    In addition, I can't get a wrench or socket on the middle exhaust manifold bolts.

    Is there some trick I don't know about or has everyone pulled the engine to swap cylinders & pistions?

  2. #2

    Join Date
    Jun 2012
    Swartz Creek Michigan
    I just did a 95 sl yes it is doable. The expansion pipes mounts need to be loosened or removed.
    After pipe is loose then remove manifold from hull....then pipe.

  3. #3 much for the 780? stimpsonjcat's Avatar
    Join Date
    Apr 2012
    Georgia - Lake Lanier - near 6TH
    Yeah I had to pry on the fiberglass to get one of the bolts out. I trimmed about 5 threads off to make reinstallation easier.

    Once the exhaust pipe is loose you slide it forward to get at the rest of the exh bolts.

  4. #4

    Join Date
    Jul 2012
    Ludlow, KY
    Like Blackwoodz said.. I also have just finished removing and installing a SL 750 #2 Cylinder and piston without pulling the engine. I used a 1/4 ratchet and socket set for the exhaust manifold bolts. I removed the water intake, cylinder head and air intake housing which all are easy to do. Then was right there for the 4 nuts on the cylinder mount to the block. I used a little gasket sealer in my socket when installing and removing the nuts not to drop them back down into the engine. It was a lot simpler than I thought.. It took me about 2 hrs to do.

  5. #5
    Okay, thanks for the advice. I'll try again with a little more effort!

  6. #6
    RLACEMAN's Avatar
    Join Date
    Aug 2011
    Random Lake WI
    The 780 is different than the 750, much harder because the exhaust is higher & sits farther out from the engine, but can be done, you have to remove all the manifold bolts to get the pipe out, you need a variety of socket extensions 3/8" & 1/4" sizes & the ratcheting box wrenches are a help with this project. I did it last year on an slx 780, don't want to ever do it again!

  7. #7
    Doesn't sound so good now, but will try. If there are any other hints, I'll sure take them.

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