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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Got the muffler off! (renamed) /cgi-bin/YaBB.pl?num=1193343616 Message started by islandwahine on 10/25/07 at 13:20:16 |
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Title: Got the muffler off! (renamed) Post by islandwahine on 10/25/07 at 13:20:16 Hmmmmphhhh!!! Remember my little muffler shield problem? http://w3.bikepics.com/pics/2007%5C10%5C16%5Cbikepics-1058053-800.jpg I got the nut off believe it or not, tapped slowly at the bracket with hammer and stubby flathead screwdriver, and lots of W-40. After some amazingly LOUD squeaking while turning the nut it came out. The clamp on the other side is loose. http://w3.bikepics.com/pics/2007%5C10%5C25%5Cbikepics-1066240-full.jpg It's not coming away though. And the muffler shield itself is still solidly mounted. I looked at Clymers, but couldn't find any reference on how to remove the big shield, only the little one in front. Isn't this thing supposed to come off once you've got the nut off? |
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Title: Re: ??? Isn't this supposed to come off now??? Post by verslagen1 on 10/25/07 at 13:39:03 Take a look from underneath. I think there's 2 more screws hidden somewhere. |
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Title: Re: ??? Isn't this supposed to come off now??? Post by youzguyz on 10/25/07 at 13:42:46 I think they are on the backside of that "fin" that sticks up. May not be able to see it from underneath, but should be able to feel them from the top. Might have to take exhaust completely off to get to them though?? Durned if I know, mine isn't stock. |
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Title: Re: ??? Isn't this supposed to come off now??? Post by islandwahine on 10/25/07 at 13:57:17 I did find the reference in Clymer's, and they did say to only take the bolt and clamp off and then remove shield. Oh well, what the heck! Think I'm going to bench the bike for a while. Need to replace the gasket anyways, might as well take the whole darn thing off. Say! The engine is not gonna drop tot the ground when I remove the front heat shield and foot peg? The other bolt will hold it up right? Or do I need to support the engine with a jack or something while doing this? |
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Title: Re: ??? Isn't this supposed to come off now??? Post by youzguyz on 10/25/07 at 14:06:52 islandwahine wrote:
Noooo.. the engine will stay where it is. Shouldn't even move. Lots more bolts holding it in! ;D And you don't pull the bolts out anyway. The heat shield and footpeg slide off the bolts. Just remember that those 2 bolts (engine mount/foot peg/small heat shield) have to get REAL tight when putting them back on. About 55 ft/lb |
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Title: Re: ??? Isn't this supposed to come off now??? Post by demin on 10/25/07 at 14:08:02 No the engine won't fall,leave your top mount bolted up. |
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Title: Re: ??? Isn't this supposed to come off now??? Post by vtail on 10/25/07 at 14:23:11 There are 2 philips head screw on the inside. Little hard to see or get to ;) |
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Title: Re: ??? Isn't this supposed to come off now??? Post by islandwahine on 10/25/07 at 15:09:42 Thanks guys! Just finished cleaning carport, and putting new paper on table. (you know me... got to write and tape it all down). 55 ft/lbs Hmmmm... Who was that again that posted that little torque per inch/foot stuff? I saw a wrench that had torque measurements on it, really cool, really expensive..$104 OY! |
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Title: Re: ??? Isn't this supposed to come off now??? Post by islandwahine on 10/25/07 at 15:26:53 vtail wrote:
You are RIGHT!! Found them with a mirror and a flash light. WHAT KIND OF MORON WOULD DESIGN THAT THING WITH THE SCREWS INSIDE!! Cr_p! Of course they are utterly rusted! I put some liquid wrench on it, gonna let it soak for a while! |
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Title: Re: ??? Isn't this supposed to come off now??? Post by islandwahine on 10/25/07 at 16:22:53 ok, I'm kinda stuck! Can not get those philips screws off, so I decided to take the muffler holder off. took the bolt on left right side of bike off, bolt on left side is hidden. I can see the end of the bolt coming out but don't really see the head on left side of bike. So I decided different tactic; get front of muffler off, remove small heat shield and foot peg. Top nut came off (after a lot of turning. bottom nut.... I'm turning and turning and turning and........ I think I've turned it at least 50 times. It is not getting loose enough to turn by hand, but turns easily with wrench. but nut is not coming off. What do you think is going on??? Got to get that off to get the muffler pipe off. |
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Title: Re: ??? Isn't this supposed to come off now??? Post by SavageDude on 10/25/07 at 16:40:14 IW, you need to have another wrench to keep the bolt from moving while you loosen the nut. Otherwise the darn thing will keep on spinning around and around forever. The head of the bolt is wayyyyy on the other side :) Happy wrenching. |
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Title: Re: ??? Isn't this supposed to come off now??? Post by SavageDude on 10/25/07 at 16:44:38 BTW you also need to loosen up the 2 nuts on the header/exhaust port to easily remove the muffler w/t shield on. Believe me I've been there ::) Stupid Suzuki engineer >:( |
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Title: Re: ??? Isn't this supposed to come off now??? Post by islandwahine on 10/25/07 at 16:49:10 SavageDude wrote:
:-[ :-[ I feel like such an idiot!! The top one came off without having to hold another bolt, so I didn't think the bottom would be any different! Do I need to take the brake cable off? It's kinda tight and there's not enough room to slide the footpeg off the bolts. |
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Title: Re: ??? Isn't this supposed to come off now??? Post by islandwahine on 10/25/07 at 18:56:09 SavageDude wrote:
That was so easy to do it that way!! I got to write that Clymer's fellow about this! The 2 idiotic screws actually came of without too much trouble. I'm soaking the 2 muffler pieces, they are kinda rusted together. |
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Title: Re: Got the muffler off! (renamed) Post by islandwahine on 10/25/07 at 19:00:41 Is there supposed to be soot where the muffler meets the engine? http://w3.bikepics.com/pics/2007%5C10%5C25%5Cbikepics-1066933-800.jpg There is also some in the beginning of the pipe. http://w3.bikepics.com/pics/2007%5C10%5C25%5Cbikepics-1066934-800.jpg I'm gonna have my hands full getting the rust off this one. http://w3.bikepics.com/pics/2007%5C10%5C25%5Cbikepics-1066935-800.jpg The shield bracket is just a little crooked! http://w3.bikepics.com/pics/2007%5C10%5C25%5Cbikepics-1066936-800.jpg Got lucky though! no hole in the muffler, but 2 nice size dents! |
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Title: Re: Got the muffler off! (renamed) Post by islandwahine on 10/25/07 at 19:59:50 How does one get the 2 muffler pieces apart? I sprayed it thoroughly with liquid wrench, but they are pretty stuck. And yes, I did remove the clamp. the pieces don't even swivel! so I guess they are rusted together pretty good! |
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Title: Re: Got the muffler off! (renamed) Post by SteveRocket on 10/25/07 at 20:15:52 It can be very difficult and even a two man or woman job. If you can get it in a vice the gently try separating them by moving the non gripped end backward and forwardand side to side. The way I did mine without a vice was to put wood underneath it to try to prevent damage stand it on it's end and force a small chisel or old screwdriver between the parts where they meet. You will probably have to hammer it in and wiggle it about. There is usually a part where the header goes into the muffler and I forced a small chisel down there moving it round a bit at a time. The idea is to open up the flange to release the pipe inside. Dont peel the outside part back too much. I hope that helps a little Steve |
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Title: Re: Got the muffler off! (renamed) Post by verslagen1 on 10/25/07 at 20:21:07 Unless you going to replace the muffler, I'd leave them together. But they are just pressed together. |
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Title: Re: Got the muffler off! (renamed) Post by islandwahine on 10/25/07 at 20:22:37 Thanks, got it off! By the way.... Does anyone know if the clamp that snugs the gasket to the engine is supposed to be concave? I thought it was normally flat. I put it against the engine by itself, and it wobbles. Doesn't flush against it at all. |
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Title: Re: Got the muffler off! (renamed) Post by islandwahine on 10/25/07 at 20:24:46 verslagen1 wrote:
I was going to try and get the rust off, and maybe coat it with enamel or heat resistant paint. If I don't do something about the rust, I will have to replace the muffler within a year. I'd rather not o this again! |
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Title: Re: Got the muffler off! (renamed) Post by SavageDude on 10/26/07 at 18:38:29 islandwahine wrote:
Uh hum! I hope you have new header gasket. Which way is it concave (outside or inside)? According to what I see on my bike (05 S40), the clamp is flat on the outside and I don't remember what shape it was on the inside! Anywho, when retighten them you have do it evenly on both side and bring them up to the TORQUE value. If not you will either strip the threat or break-off the studs :o |
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Title: Re: Got the muffler off! (renamed) Post by islandwahine on 10/26/07 at 21:58:26 SavageDude wrote:
I'm ordering a bunch of stuff from BikeBandit, including gasket. Most of the screw/bolts were pretty rusty and are not re usable. Also the the previous owner used 2 different screws to tighten the muffler clamp to the engine. The gasket itself is flat but the clamp that clamps on the pipe to the engine block is concave on the inside, it looked warped! When it was attached it looked crooked and off, and it looks like the soot is directional, so maybe the clamp did not seal all the way. Also need a new gasket/sealer thing that's in between the muffler and the pipe. I'm having some trouble figuring out the number system on BikeBandits diagram for the parts.` |
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Title: Re: Got the muffler off! (renamed) Post by verslagen1 on 10/26/07 at 22:16:22 bb p/n 484442-001 it's #8 in the gasket page |
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Title: Re: Got the muffler off! (renamed) Post by islandwahine on 10/27/07 at 03:25:05 Hmmm, I punched in the number, but BikeBandit did not recognize it. I could not find a gasket page. I think it is part number 5 on this page. 484930-001 http://houseofmotorcycles.bikebandit.com/partsbandit/assets/schematics/Suzuki/SU0145_014.gif http://houseofmotorcycles.bikebandit.com/parts/Suzuki/LS650PX+SAVAGE/1999/707762 |
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Title: Re: Got the muffler off! (renamed) Post by LANCER on 10/27/07 at 04:30:50 http://w3.bikepics.com/pics/2007%5C10%5C25%5Cbikepics-1066935-800.jpg oooooooooooooooH ......... RRRRRRUUUUUUUUUUSSSSSSTTTTT NASTY NASTY NASTY Have you thought about building your own header? Looks like it is time to consider it. :P It is fun thing to do. ;D You can get a small welder for about a $100 or so ... well, maybe a bit more since you are way out there in the deep water and isolated on that rock with trees, flowers, fresh breezes and young healthy females running around the beaches with those tiny little pieces of material they call bathing suits ......... ::) OK, back to reality, but it was a fun fantasy for a second there. Anyway, TRY IT- YOU'LL LIKE IT ! ;) |
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Title: Re: Got the muffler off! (renamed) Post by SavageDude on 10/27/07 at 09:41:38 islandwahine wrote:
IW, Lancer is right. But if you're on tight budget, you could sand the whole thing down then get some paint that is design to paint barbeque grill (flat or gloss black). From what you describe the condition of the clamp, you might as well order a new one (#3) and a new gasket (#2) + (#5)+ 2 (#4). I just order a bunch of stuff ($80) from RonAyers.com and free shipping. I ordered stuffs that I dont need need yet but will in the future. Shipping fee is a killer :o |
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Title: Re: Got the muffler off! (renamed) Post by islandwahine on 10/27/07 at 13:11:13 SavageDude wrote:
Well if there is one thing I've learned, is that FREE SHIPPING does not apply to Hawaii (or Alaska for that matter). I've learned to read the shipping policies before ordering stuff. The only company that honors the free shipping even to Hawaii is Amazon.com. :o Just thought of something, maybe they would like to start a different branch of products!!! :o I'm also gonna need #6 and #7 (totally rusted out). |
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