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Message started by bill67 on 10/13/07 at 12:59:37

Title: How to take off stock muffler
Post by bill67 on 10/13/07 at 12:59:37

I got everything loose and can turn muffller but it want come off .I can turn it still want pull back . I dont have head pipe off and I didnt want to take it off. Anybody have an idea what to do.

Title: Re: How to take off stock muffler
Post by Paladin on 10/13/07 at 13:01:07

I had to loosen the headpipe where it attached to the cylinderhead before I could replace my muffler.

Title: Re: How to take off stock muffler
Post by bill67 on 10/13/07 at 13:05:11

Southerngirl said she did hers without taking off head pipe but I guess I will have to take it off or loosen it thanks.

Title: Re: How to take off stock muffler
Post by Baldeagle on 10/13/07 at 13:15:13

Started at header and worked back which requires you to remove heat shield at foot peg. Removed two bolts holding muff Laid on work bench to loosen clamp. Replaced both gaskets.

Will work better if you remove the other heat shield but I started rounding off the phillips screws.

Good luck and ride safe!!!!!

Title: Re: How to take off stock muffler
Post by bill67 on 10/13/07 at 13:21:31

I have the heatsheild off every thing is losse but muffler want come off. Im resting now thinking about it

Title: Re: How to take off stock muffler
Post by thumperclone on 10/13/07 at 13:40:53

tryin to remember: think i left heat shield attached layed on my back had wifey straddle front tyre and hold handle bars..i got under muff best i could and put foot on foot peg, twisted and pulled muff till it came off..back when my 06 was under 1500 miles...good luck!!!
edit: think i cramed the handle of a pair of channel loks into muffs bolt channel..< still fuzzy on this part..

Title: Re: How to take off stock muffler
Post by bill67 on 10/13/07 at 13:49:08

Mines and 06 with 950 miles . im waiting for my windsheild to come in I dont like riding without one.

Title: Re: How to take off stock muffler
Post by vtail on 10/13/07 at 14:12:40

There's a metal bracket that supports the muffler. Loose the 2 allen bolts (for the left one you'll have to remove the beltpulley cover,and mark where each of the three bolts go since they're all different lengths and do not lose the rubbers and spacers) Then remove the bolt on the right side forward of that bracket. Remove metal spacers inside the rubber grommets that hold muffler in space and rotate bracket downwards. Then slowly wiggle muffler off. If it will not come off without reasonable twisting and pulling, just remove header pipe so someone can hold that or clamp header pipe in vice (with lots of cardboard as not to scratch that). When installing another muffler make sure you retorque Exhaust pipe clamp bolts to approx 16 ft/lbs and use a preferable new sealer gasket wher the header pipe meets the muffler ;)

Title: Re: How to take off stock muffler
Post by bill67 on 10/13/07 at 14:15:44

Every thing is loose the muffler just want come off I keep turning it back and fore trying to make it looser

Title: Re: How to take off stock muffler
Post by vtail on 10/13/07 at 14:17:28

Bill our replies crossed each other. Check mine above yours. Getting that support bracket out of the way is important :)

Title: Re: How to take off stock muffler
Post by bill67 on 10/13/07 at 14:19:15

I have all the brackets off its the muffler want come off head pipe.

Title: Re: How to take off stock muffler
Post by vtail on 10/13/07 at 14:24:46

If it will not come off without reasonable twisting and pulling, just remove header pipe so someone can hold that or clamp header pipe in vice (with lots of cardboard as not to scratch that). When installing another muffler make sure you retorque Exhaust pipe clamp bolts to approx 16 ft/lbs and use a preferable new sealer gasket wher the header pipe meets the muffler
Did you rotate the muffler support bracket out of the way? :)

Title: Re: How to take off stock muffler
Post by bill67 on 10/13/07 at 14:26:23

OK thanks

Title: Re: How to take off stock muffler
Post by vtail on 10/13/07 at 14:29:41

Pulling to hard on the muffler is really hard on the exhaust pipe clamp bolts. Read my 2:12 pm posting :)

Title: Re: How to take off stock muffler
Post by Rockin_John on 10/14/07 at 09:55:45

Ever get this muffler off? If not, try going around the flange of the muffler with a small cold chisel to swag it open a bit at the very end; then use something thinner to drive farther into the opening.

What happens is: The end of the header pipe that the muffler flange goes over is kind of bulb shaped, and the original clamp pulls the flanges of the muffler pipe down around the "bulb." So, you have to open up the header end of the muffler a bit so it can slip over the widest part of the header end. Don't get too aggressive on any one side, lest you make the other side tighter.

Then wiggling and pulling should make the stubborn muffler pop off. :)

edit: Of course this is the "women and children" method of getting stubborn metal objects apart. Real men just grab hold like alligator wrestling; putting one foot on the foot peg and just yank the SOB off there! If the "real man" is lucky, he doesn't snap the header bolts off at the jug.

Title: Re: How to take off stock muffler.
Post by bill67 on 10/14/07 at 10:44:02

Yes i got it off without taking off the head pipe it just took sometime . im working on the muffler to make it quieter with some baffles and fiberglass wrap its a emgo muffler its not straight threw.

Title: Re: How to take off stock muffler
Post by YonuhAdisi on 10/14/07 at 10:52:41

Rockin_John wrote:

If the "real man" is lucky, he doesn't snap the header bolts off at the jug.

Also if the "real man" is lucky he won't suddenly fall back and crack his head against the garage/carport floor when the muffler suddenly releases from the header pipe.

(rubs back of head still feeling that knot.) Don't ask. :-[ :-[

Title: Re: How to take off stock muffler
Post by bill67 on 10/14/07 at 11:11:13

Southerngirl help me pretty much with pms.