SuzukiSavage.com - How do I take off the Stock muffler?

hunnus2000 Ex Member	How do I take off the Stock muffler? 12/28/06 at 14:27:27 OK, I got the SuperTrapp in but how do I take off the stock muffler?? There look to be 4 bolts and two of the bolts are near the rear wheel and that's what's giving me problems. I took the bolts off but the screws just stick in there. Is it rust???? Arrrgh!
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necropsy Full Member 2005 No Login Offline Suzuki '05 S40 Posts: 173 Barrie, Ontario, Canada Gender:	Re: How do I take off the Stock muffler? Reply #1 - 12/28/06 at 14:46:15 Your going to have to remove the 2 bolts at the head to header connection, (the two that go into the exhaust port on the engine head) and the two nuts under the exhaust bracket. (the bracket that supports the muffler). Remove the entire exhaust system and dismantle it from there.
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: How do I take off the Stock muffler? Reply #2 - 12/28/06 at 15:12:28 Gotta get the muffler clamp loose too. A squirt or 2 of WD-40 on all bolts and connections may be a great help too. Be sure to use the anti-seize generously on the disks bolts too. Don't skimp.
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hunnus2000

Ex Member

Re: How do I take off the Stock muffler?
Reply #3 - 12/28/06 at 15:15:09

necropsy wrote on 12/31/69 at 16:00:12:

Your going to have to remove the 2 bolts at the head to header connection, (the two that go into the exhaust port on the engine head) and the two nuts under the exhaust bracket. (the bracket that supports the muffler). Remove the entire exhaust system and dismantle it from there.

Thank You!

But the rear bolts near the back tire are the problem. There is no slide area like there is on the ST, so to speak, for the bolts to move freely but rather holes for the bolts. Therefore it can't slide out without removing the bolts first and the bolts physically cannot come out.

Are you saying I need to remove the header also? ???

OK, 2 cases of beer if someone comes out and intalls this pipe!!! Grin

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Savage_Greg

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Don't go around your
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Re: How do I take off the Stock muffler?
Reply #4 - 12/28/06 at 15:25:24

I don't like to disagree, but you don't HAVE to remove the header to install the Trapp. It's more work than necessary because you'll have to mess with the brake pedal/ cable too...But loosening the header bolts will definitely help to line it up again.

Also, are you trying to remove the heat shield on the stock muffler?

Here, check the Ron Ayers schematic...

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Fat Bastard

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Re: How do I take off the Stock muffler?
Reply #5 - 12/28/06 at 15:30:06

Yank it off... use the force.. that what I did.. I had the same problem.... the darned thing would come off... so I just bent the bracket down and pulled all I had..... I don't remember if you can loosen the bracket where it bolts to the frame.. I 'm not going out to the freezing garage now in my jammies..... but you can see what I did here.. (scroll down)
http://suzukisavage.com/cgi-bin/YaBB.pl?board=RubberSideDown;action=display;n...

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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: How do I take off the Stock muffler? Reply #6 - 12/28/06 at 15:37:39 When reason doesn't work, there's always other options Do it like a dealer would. Get a bigger hammer!
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hunnus2000

Ex Member

Re: How do I take off the Stock muffler?
Reply #7 - 12/28/06 at 16:29:43

Savage_Greg wrote on 12/31/69 at 16:00:12:

I don't like to disagree, but you don't HAVE to remove the header to install the Trapp. It's more work than necessary because you'll have to mess with the brake pedal/ cable too...But loosening the header bolts will definitely help to line it up again.

Also, are you trying to remove the heat shield on the stock muffler?

Here, check the Ron Ayers schematic...

http://i21.photobucket.com/albums/b277/gmdinusa/muffler.jpg

Thanks again! That schematic puts it onto perspective and loosening the header bolts makes perfect sense.

Luckily I have an extra set of hands!

I'll let ya'll kno w tomorrow.

BTW, I called the dealership to get some advice and they told me that they don't recommend replacing the stock pipe;
I fully expected that answer............. Cheesy

Removing the heat shield??????????? ???

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Steve530

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Re: How do I take off the Stock muffler?
Reply #8 - 12/28/06 at 17:14:38

To remove the rear heat shield, just remove bolt #14, then the back part of the clamp #13.

To remove the forward heat shield, you have to remove the two acorn nuts at the bottom of the shield. Note that these bolts go through the engine case with the heads on the other side of the engine. I think you'll have to hold the heads to remove the nuts. Do not remove the bolts.

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'97 Black / 1/2 white spacer
155 main jet / 55 pilot jet / Dyna muffler
snorkel removed / K&N drop in / seat raised
Slipstreamer SS30 windshield

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justin_o_guy

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Re: How do I take off the Stock muffler?
Reply #9 - 12/28/06 at 17:48:43

My stock muffler just hit the floor. The bracket that it is mounted to at the rear is secured in 3 places. I was already short 1 bolt so I dropped another & that allowed me to get the studs out & rotate the muffler. Then it just slid off. However, this is an o5 with 13,500 miles so maybe it would be a lot harder with an older bike.Bolt#7 was all the way out & I think that helped. #16 was missing, gotta get another cuz that allows the exhaust to swing around & make leaks. The header pipe wiggles at the head now so I guess I trashed that gasket, dunno but I am replacing it & gonna clean up exhaust port a bit.

Greg, thanks for the Schizophrenic diagram.

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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: How do I take off the Stock muffler? Reply #10 - 12/29/06 at 05:42:42 Welcome. All those diagrams are available at Ron Ayers if you don't have a manual. You can right click and download any of them for your projects. Notice the weight difference between stock and Trapp?
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