Blaster Help: Broke Exhaust Mount Bolts

[Adam E.]

I discovered that I had broken all three bolts that attach my exhaust to the cylinder head. I wasn't jumping hard at all and I have no idea how these all completely sheared off. Needless to say I noticed reduced power as I was just putting my ski on the trailer. As you can tell from the pictures the smaller cooling line popped off. I'm concerned that I may have damaged the ski? A quick compression check revealed equal 160/160 compression.

My questions are:
1. Do you think damage occured?
2. How would you suggest handling the situation: A) Attempt to remove sheared bolts through tap/die B) Buy a new exhaust?
3. What is the easiest manner to remove the exhaust? At what point would you take it off to minimize parts removed/gaskets removed etc..?

Thank you in advance.

Adam

 

[Mdavies_02]

Other than a little wear on the rubber couplers I strongly believe no damage would have occurred. That said I would remove the exhaust chamber (should be a Tech thread on the X)and try to remove the damaged bolts with a simple kit sold at Harbor Freight. If that didn't succeed I would recommend purchasing a used chamber as it is stock and everyone has one laying around rather than taking it to a machinist.

That's how I would approach it. Welcome to the world of wrenching.

 

[Johnny Africa]

Buy an after market exhaust & unleash the potential that engine has. Kinda unusual that you sheared those bolts off...

 

[Adam E.]

Thank you both for the replies. I will attempt to remove the sheared bolts myself first. That being said I am unsure which approach is best to take off the exhaust. Would it be option (A) separate the chamber or (B) remove where it connects to the exhaust manifold?

 

[Mdavies_02]

To remove the stock exhaust chamber do the following

- Remove top hose clamp on the coupler located just below A on diagram listed on diagram as #7
- Slide back coupler to reveal interior coupler (May want to spray some WD40 to aid in slide)
- Remove interior coupler hose clamp listed on diagram as #8
- Remove lower hose clamp on bottom side of chamber listed on diagram as #5 (Coming off the hose to the waterbox #6)

That said, I haven't done it in 5 years. Like Johnny Africa said almost everyone ditches that exhaust and goes A/M to see massive performance gains.

Good luck