1999 GTX Limited, exhaust removal?

[TubecatGS]

I can't seem to find any posts with a step by step guide to remove the exhaust. I have worked on ATVs and cars for 30 years but know nothing about these skis yet. I am going to replace the grey fuel lines, oil tank leaks (ordered new one and grommets) but want to replace some oil lines and clean the hull as oil must have been leaking for a long time on and off.

 

[SabrToothSqrl]

you have to remove the 2-3 bolts, but there's also a nut under it that you have to remove the carbs for first.

 

[mikidymac]

It is much easier if you don't remove the pipe if you can help it.

 

[TubecatGS]

It is much easier if you don't remove the pipe if you can help it.

So by removing the carbs, will there be enough room to get hands in there to replace fuel and oil lines?

 

[mikidymac]

Yes but not the easiest.

The big issue with removing the pipe is that they are a pain to realign and reseal.

 

[SabrToothSqrl]

Correct, you need not remove the pipe to change the fuel lines... I wasn't thinking of the to do, just the question.

you can remove the carbs to make it easier. you'd have to remove them anyway to get the lines between the carbs.

 

[POPPS]

Trust me, do not remove the pipe,,,it will be a nightmare reinstalling it,,,and if you do, do it in 1 piece. Why replace the oil lines?,,,they rarely leak.

 

[TubecatGS]

Trust me, do not remove the pipe,,,it will be a nightmare reinstalling it,,,and if you do, do it in 1 piece. Why replace the oil lines?,,,they rarely leak.

While I was replacing the tank I figured replace the oil filter and main line to pump. I was able to replace the oil tank, grommets, oil filter, main oil line to pump and all the 6mm grey fuel lines (still need to replace larger 8mm lines all without removing the exhaust.... going to prime and fire it up over the next day or so I hope. Thanks all.

 

[mikidymac]

You should replace all the gray lines and the little 3/32” oil lines from the oil pump to the intake manifold.

 

[TubecatGS]

You should replace all the gray lines and the little 3/32” oil lines from the oil pump to the intake manifold.

Yes as soon as I find black fuel lines that fit the 8mm fittings.. I have the 3/32 oil lines lines already. Do you have to remove the carbs to change them?

 

[mikidymac]

It’s much easier.
For the 951 all supply lines are 5/16” automotive fuel hose available anywhere. Only the return is 1/4” and again available anywhere.

 

[etemplet]

That pipe.....I hate the miserable bastich it's a SOB to work around. I didn't think it would come out in one piece. I need a video POPPS. I do mostly engines with the 951 so when I work on a 951 I'm generally removing the exhaust. In order to get the pipe positioned back in place and mounted properly, near as I can tell you gotta string together the right amount of curse words and in proper sequence.

This pipe ain't got nuthin on the 1200 Yamaha.

 

[SabrToothSqrl]

on the 02 XP you can remove/reinstall the pipe without splitting it... on the GTX... I don't think you can.

 

[etemplet]

Splitting the Pipe itsn't all that bad if you do it enough I guess. It would be easier sometimes with another pair of hands but it goes right together. Of course, some dumbazz always puts the clamp bolt facing the wrong way when you are taking them apart. LOL Hands down the bestus easiest set up for me is the DI throttle bodies. Takes about a minute to remove them. I did a starter on a DI without pulling the exhaust. I guess we pick our battles. Ha ha. Touchdowns everyone !

 

[andy.262]

on the 02 XP you can remove/reinstall the pipe without splitting it... on the GTX... I don't think you can.

I have removed and re-installed the pipe without splitting it on my 99 GTX LTD before. It helps a ton to have a helper, and I think I may have also removed the driveline and loosened the engine mount bolts a little bit so I could shift the engine around just a touch (the engine was coming out anyways). Its a PIA for sure. Without removing the driveline I'm not sure you could do it. Certainly for the job being discussed in this thread it's not really worth it to remove it anyways.

 

[TubecatGS]

Thanks all. Ended up replacing as much as I could without removing the exhaust. Fired it up for the first time last night. Runs but bogs down and then takes off. Will start a new thread on that topic. Thanks again all.