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S40 muffler removal (Read 12 times)
wingdwolf56
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S40 muffler removal
10/20/05 at 13:41:15
 
Will someone please detail an S40 stock muffler removal? I'm lost!
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slavy
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Phoenix, Arizona
Gender: male
Re: S40 muffler removal
Reply #1 - 10/20/05 at 19:43:07
 
Remove the 2 right side footpeg bracket nuts.
Remove the 2 bolts that hold the header to the cyl. head
Remove the 2 nuts that hold the muffler to the muffler bracket /they are between the muffler and the rear wheel/
Remove the whole pipe assy
Remove the heat shield - 2 philips screws and a bolt for the heat shield clamp
Losen the muffler clamp and spray liberaly WD40 in the connection between the header and the muffler.
Twist, turn and pull on the header and the muffler untill
they separate.
   You can try to just take apart the heat shield clamp and losen the muffler clamp.After that You take off the 2 nuts that hold the muffler to the muffler bracket .Pull apart the muffler from the header. But in a long run it will be easier to go the first road. Seems more work, but it is easier.
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The arificial intelligence is no match for the natural stupidity
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wingdwolf56
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Re: S40 muffler removal
Reply #2 - 10/21/05 at 11:55:25
 
Thanks..I kinda figured I'd have to remove the whole thing. I was hoping to avoid that...but..oh well...Thanks Again!
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vroom1776
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Re: S40 muffler removal
Reply #3 - 10/21/05 at 13:36:03
 
I did get my muffler off without removing the whole exhaust assembly, but I needed help. My frieed pulled on it, out and back,  while I held the bike in place, after I loosened the appropriate bolts & nuts.  No damage.

Now if someone would figure out an easy way to get the tank on and off...  what a PITA!  Angry  On my other two bikes, GT removal & unremoval is very easy...
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barb36jack31
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Heathrow, FL
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Re: S40 muffler removal
Reply #4 - 10/21/05 at 18:39:29
 
For Slavy -  Thanks for the complete info re removing the muffler on the S40.  Very clear and to the point.  Any recommendations for a replacement?  Mac, SuperTrapp?

I am looking for a solid, low thumper sound rather than a LOUD pipe.  I have used SuperTrapp in the past on both a Suzuki DR 250 and  Kawasaki KLR 650.  Loved them both.

Jack H.
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05 S40 , air needle adjustment, white spacer, 152.5 main jet, K&N filter, SuperTrapp muffler, Progressive shocks , sissy bar off
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