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Message started by ohms on 07/14/06 at 18:52:54

Title: muffler removal
Post by ohms on 07/14/06 at 18:52:54

Hi everyone, new to the forum and the motorbike world. Had my suzuki for a few months now (First Bike). Just got a jardine pipe and k&n filter and some new jets to try and get some more power out of her.

Im just pulling the bike apart now but i've run into a snag. Im trying to remove the muffler from the header pipe but the darn thing isnt budging ive been fighting with it now for over an hour. Is there an easy way to do this. I dont want to beat with a hammer as might damage something. I'm sure a lot of you have done this before. Can someone please tell me how they got this thing off?

Thanks

Title: Re: muffler removal
Post by SavageDude on 07/14/06 at 19:42:46

Loosen/remove the two bolt that hold the header two the exhaust port. This will give you more wiggle room to get the muffler out of the two mounting holes in the back; then you you can remove the muffler from the header.

Happy wrenching ;D

Title: Re: muffler removal
Post by Brewbrother on 07/14/06 at 20:03:27

Careful with that hammer Eugene.

Title: Re: muffler removal
Post by cstout on 07/14/06 at 20:40:29

I had trouble with mine, too. You just have to keep wiggling it back and forth and pulling on it at the same time. Like SavageDude suggested, loosen the header bolts to give you more wiggle room. It will eventually come off, you just have to convince it that you won't take no for an answer.

It may be helpful to have a friend hold the front of the bike so you can pull harder without the whole bike chasing you across the garage floor.

Title: Re: muffler removal
Post by necropsy on 07/15/06 at 07:38:39

Remove the heat shield at the foot peg.
Remove the the bolts holding the header pipe to the head.
Remove nuts on muffler hanger.
Remove entire exhaust (header and muffler).
Seperate.
The whole exhaust should be removed to seperate them, and the header gasket should be replaced. Just loosening the header bolts and wiggling will make a mess of that header gasket and cause severe backfiring.

Title: Re: muffler removal
Post by ohms on 07/15/06 at 13:17:13

Thanks for sending me on the right track. I removed the whole exhaust, and from there with much fighting and cursing was able to remove the muffler from the pipe. The whole end of the header pipe is really rusted, should I use some sandpaper and sand off the rust?

So let me know if I have this whole process straight. Now that i have separated the muffler, I replace the two gaskets (header and muffler). Assemble the new muffler and the old header pipe with new muffler gasket and some high temp silicone sealer. Put the new exhaust back on the bike replacing the header gasket and make sure the mounting holes for the muffler line up with the frame. That sound right?

Title: Re: muffler removal
Post by 911radioman on 07/15/06 at 14:19:15

You're on the right track.

When you assemble the new muffler/header on the bench, don't tighten it all up. Get it put together, then get it back on the bike so you can get everything aligned properly, then torque the muffler down tight.

When you torque your header bolts, it will take you 3-4 times to get them torqued down all the way. What I do is run it a few days, then come back and put a little more torque to the header bolts. Continue that for a few times and eventually you'll have them where they will be tight and stay tight.

Title: Re: muffler removal
Post by Steve530 on 07/15/06 at 21:36:38

Remember to use anti-sieze on those header bolts and be careful when torquing the bolts. Resist the urge to over-tighten. They're steel and the head is aluminum.