SuzukiSavage.com - muffler removal

ohms

Ex Member

muffler removal
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

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SavageDude Serious Thumper Alliance Member Offline Posts: 561 OC_California Gender:	Re: muffler removal Reply #1 - 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
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Brewbrother Serious Thumper Offline Just lending a helping hand. Posts: 953 Gender:	Re: muffler removal Reply #2 - 07/14/06 at 20:03:27 Careful with that hammer Eugene.
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enophile

Full Member

Offline

1998 Savage, black,
mostly stock

Posts: 116
Morgantown, WV
Gender: male

Re: muffler removal
Reply #3 - 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.

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The number of cylinders isn't important...it's how you use them.

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necropsy

Full Member
2005 No Login

Offline

Suzuki '05 S40

Posts: 173
Barrie, Ontario, Canada
Gender: male

Re: muffler removal
Reply #4 - 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.

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Music calms the SAVAGE beast

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ohms

Ex Member

Re: muffler removal
Reply #5 - 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?

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911radioman

Ex Member

Re: muffler removal
Reply #6 - 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.

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Steve530 Senior Member 2005 No Login Offline Posts: 452 Knoxville, TN Gender:	Re: muffler removal Reply #7 - 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.
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