Midsection Removal

[charlesretired]

2000 Yamaha Z200TXRY HPDI

Does any one know if the mid section can be removed while the motor is attached to the bracket in order to inspect / replace the exhaust manifold and muffler gaskets. If so are there any tricks to remove ?? I know the bottom gear case has to be dropped typical of water pump service.

Thanks in advance Captain Charles

PS: I want to do this without removing the power head if at all possible.

[rodbolt17]

remove lower,remove the powerhead.
remove bottom cowl and rigging.
remove lower mount covers.
remove nuts on upper and lower mounts.
make sure you remove the bonding wire at the bottom of the midsection.
slide midsection from bracket assy.have not seen a failure of the ex stack on a Z200.
Z250,Z300 and some V6 F motors but never a 2.6L Z motor,
why do you think its failed?

[charlesretired]

Mid section remoal

Rodbolt 17

Not sure what has failed, howevr I have exhaust smoke rising up from the front of the motor. Not a lot, but enough that you can see and smell it. It comes out of the area where the steering arm goes thru the plastic cowling. It is deffinetly ehaust and not steam, it will do it when motor is running in the water but now that I have pulled it I can't get it to do it
I am assuming that there is less resistance. In previous post it was sugested that a gasket may be leaking. ?? Whatever, I have pulled the bottom end and now trying to remove the mid for inspection, however the lower mount bolts have me hung up , seems to me they should have been put in from the opposite direction. Also with the little play that I have it will not part at the top, I have loosened the 2 bolts in the front next to the steering arm and also the 2 in the rear that come down from above.
Thanks !!!

[rodbolt17]

once the powerhead,lower cowl and lower unit are off.
remove the 2 nuts on the upper mounts,2 nuts on the lower mounts and the midsection slides aft.
sometimes corrosion makes it a tough slide but it will.
mounts can only be removed once the midsection is off.

[charlesretired]

Mid section remoal / Rising exhaust smoke

Thanks Rod All apart, found the 1 inch thick plate (lower exhaust guide) thats directly under the ph erroded be**** the ex ports and the gasket blown also the top of the exhaust manifold stack erroded. Not sure if would cause my exhaust smoke rising out the front , but it may deter the performance as the exhaust would be crossing from port to port which in turn changes the back pressure

Charles

[rodbolt17]

its gotta get fixed.
I may have an ex housing complete.
they are avalible from varous places.
easiest way is to buy a complete used mid section.

[charlesretired]

Mid section remoal/replacement

Hey Rod.....When I reassemble the exhaust stack/muffler/midsection what should I use on the new gaskets??? Shop manual does not call out any product which I find unusal. Maybe they should be dry but would like your input. When I removed the gasket from the base of the powerhead it seened to have a gray product on it. Do you have any recomendations on a product that is easily available ??

Thank You Capt Charles

[rodbolt17]

install them dry, as designed.

[charlesretired]

MANY MANY THANKS ROD and others for all your imput and help. It's great to have guys like you on a forum

Charles