96 XP top end removal trouble

[ggdog60]

96 XP exhaust manifold removal

I have a 1996 XP 787 engine and have been trying to remove the exhaust manifold from the the cylinders (top end).
I removed the 4 bolts but the gasket will not give it up.
Q: Is there more bolts im not seeing or is there a way to loosen up the gasket?

 

[Dr Honda]

4????


There are 8 bolts holding the manifold to the engine.

 

[SurfBeat]

I recently pulled my Exhaust Manifold and it had 8 Allen type screws securing the EM to the engine. You will need a T-40 Allen Torx Bit to remove them which can be purchased at any auto parts store for a couple bucks or at your local swap meet for a dime if you are thrifty like me.

 

[ggdog60]

Carbs First

Thanks for your reply
Question:
Do I have to remove the carbs first, for tool access to remove the other four bolts?
Because I can bearly see only 2 others now (I cant even get to them with a tool)

 

[rotaxrule1]

I was able to remove all bolts without taking the carbs off on my 97 GSX, which should have basically the same configuration as your 787 engine. I would not recommend it though because the bottom middle bolts start to squeeze against the fuel lines on the way out and could pinch or rip them if your not careful. I wouldnt do it again, I would just take the carbs off.

The carbs come off by 4 bolts.... very easy to loosen up. I used an allen adapter that fits to a ratchet, that should fit in there much easier than if you were using a regular allen wrench.