SuzukiSavage.com - removing existing muffler clamp bolt-NEED help

Tiefighterpilot

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removing existing muffler clamp bolt-NEED help
04/30/10 at 20:46:34

I am trying to remove the existing stock muffler. I didnt remove the header pipe.

I got the two nuts holding the rear muffler bolts removed. The bolt looks like it stuck or part of the muffler...

I am trying to remove the bolt on the clamp (between the header pipe and muffler). the heat shield is still on, as I can't get to the screws (two on the rear part of the heat shield attached to the muffler.

The heat shield gives very little room to use a wrench on the clamp's bolt. what can I use on such a tight space?

Does this sound typical? I have 2007 S40.

Thanks for your help.

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2007 S40, KN Cone Air Filter, BCB Pipe, BCB Fender and seat, Superbrace Fork Brace with guard, 55 Pilot, 155 Main, washer mod, iridium spark plug, no afterfire, some engine breaking noise

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: removing existing muffler clamp bolt-NEED help Reply #1 - 05/01/10 at 02:43:59 remove the heat shield & get some room to work with
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Tiefighterpilot Senior Member Offline Daily Rider Posts: 346 San Francisco	Re: removing existing muffler clamp bolt-NEED help Reply #2 - 05/01/10 at 03:09:25 Did you have to remove the exhaust from the bike? I can't get to the screws on the heat shield without removing the whole exhaust from the bike.
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babyhog Serious Thumper Offline Find a Cure for Breast Cancer! NOW!! Posts: 3802 WV Gender:	Re: removing existing muffler clamp bolt-NEED help Reply #3 - 05/01/10 at 05:23:02 Tiefighterpilot wrote on 05/01/10 at 03:09:25: Did you have to remove the exhaust from the bike? I can't get to the screws on the heat shield without removing the whole exhaust from the bike. I didn't remove the header and was able to get the heat shield off. Wish I could remember exactly how, sorry.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: removing existing muffler clamp bolt-NEED help Reply #4 - 05/01/10 at 08:31:37 You'll want the exhaust off to work on it. You can see from the link that once you have the header and muff off, access to the heat shield clamp and two screws the heat shield will come off. http://www.bikebandit.com/2000-suzuki-motorcycle-ls650py-savage-muffler/o/m63...
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Tiefighterpilot Senior Member Offline Daily Rider Posts: 346 San Francisco	Re: removing existing muffler clamp bolt-NEED help Reply #5 - 05/01/10 at 10:29:04 Thanks everyone! Is replacing header gasket required or only if damaged?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: removing existing muffler clamp bolt-NEED help Reply #6 - 05/01/10 at 11:24:24 only if damaged, but if ordering would be worth to have a spare on hand.
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EJID

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Re: removing existing muffler clamp bolt-NEED help
Reply #7 - 05/01/10 at 11:42:51

When I put my Dyna muff on mine, I removed the heat shield when I took off the stock muffler without any problem. When I put the new muff on, I had trouble getting it lined up as many other had, but someone suggested loosening the header bolts and you can rotate the header pipe slightly for a better angle. After doing that I was able to line things up better for a solid fit. I did find out on the first ride after doing that adjustment that I hadn't tightened down the header bolts enough and she was a popping and banging quite a bit. The next day I tightened them up more and it solved the problem.

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05 S40 15" Memphis Slim, FXDWG Bars, Moved Rear Signals, Saddlebags, Fork Bag, Mini-Tach, Raptor, Cone Filter, Fishtail Muffler, Mix Screw Out 2.5 Turns, 4" Fwd Controls, 147.5 Main/55 Pilot @ 4500

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MrBrownTX Full Member Offline Posts: 242 Caddo Mills TX Gender:	Re: removing existing muffler clamp bolt-NEED help Reply #8 - 08/05/11 at 18:08:07 Is there a trick to take the moffler off while leaving the header pipe on? I was trying to avoid that for the sake of not messing up the gasket and the seal. However I cannot seem to get at the muffler clamp bolt.
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mmosel Senior Member 2005 No Login Offline My bike is officially THUMPING now. Posts: 415 NW Oregon Gender:	Re: removing existing muffler clamp bolt-NEED help Reply #9 - 08/05/11 at 20:10:59 It's very hard to get the heat shield off without taking the whole exhaust off. I just did it this week. Just take the whole thing off, MUCH easier. Putting the header pipe back on is a no-brainer. Just make sure it's positioned right before tightening it back down.
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justin_o_guy2

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What happened?

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Re: removing existing muffler clamp bolt-NEED help
Reply #10 - 08/06/11 at 05:17:23

Jerking & banging on the header while the whole thing is held up by those 2 puny little bolts just doesnt seem like a grand idea to me. If the muffler isnt stuck hard, okay,, but I wouldnt be getting too rough with it while its mounted. Maybe its no big deal,, IDK, but I feel like its not a great idea. Anyone else have an opinion on it?

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arteacher

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Re: removing existing muffler clamp bolt-NEED help
Reply #11 - 08/06/11 at 06:51:30

I would take the whole thing off too. Chances are you will loosen up the head gasket, or worse, bend the bolts, reefing on the muffler to get it off with the header still on. Also, for the sake of two more bolts, you can stand up to work on it, rather than farting around on the floor getting into wierd contortions trying to get at things. Grin

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Gyrobob

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Re: removing existing muffler clamp bolt-NEED help
Reply #12 - 08/06/11 at 07:44:33

mmosel wrote on 08/05/11 at 20:10:59:

It's very hard to get the heat shield off without taking the whole exhaust off. I just did it this week. Just take the whole thing off, MUCH easier. Putting the header pipe back on is a no-brainer. Just make sure it's positioned right before tightening it back down.

justin_o_guy2 wrote on 08/06/11 at 05:17:23:

Jerking & banging on the header while the whole thing is held up by those 2 puny little bolts just doesnt seem like a grand idea to me. If the muffler isnt stuck hard, okay,, but I wouldnt be getting too rough with it while its mounted. Maybe its no big deal,, IDK, but I feel like its not a great idea. Anyone else have an opinion on it?

arteacher wrote on 08/06/11 at 06:51:30:

I would take the whole thing off too. Chances are you will loosen up the head gasket, or worse, bend the bolts, reefing on the muffler to get it off with the header still on. Also, for the sake of two more bolts, you can stand up to work on it, rather than farting around on the floor getting into wierd contortions trying to get at things. Grin

These guys know of what they speak. Take it off.

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MrBrownTX Full Member Offline Posts: 242 Caddo Mills TX Gender:	Re: removing existing muffler clamp bolt-NEED help Reply #13 - 08/06/11 at 07:44:49 Very good and valid points, gents. I will follow your advise.
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MrBrownTX

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Re: removing existing muffler clamp bolt-NEED help
Reply #14 - 08/06/11 at 12:02:09

Well that was super easy that way. Thanks, I took the whole thing off and then easily loosended the clamp and slid it right off, with a little wd40 help.

I did not notice a gasket at the header that was loose or fell out. I assume its just stuck to the motor still. Will that be ok as long as it is in place? Or do I need to remove it and replace it?

Also I noticed when I bolted the header back up that it was further away from the heat shield than before and pointed in toward the bike more. So I loosened it back up and lined it up how it was then tightened it back down. Was that the right thing to do?

I am ordering a drag pipe baffle with fiberglass wrap and getting an 18" piece of 1.75" tail pipe from autozone to put on there now!!! I also am going to rejet the carb too (because I know that advice was coming).

I am so excited to have turned my own wrench on the bike. I don't usually do this and I am happy that I did. It was easy and I feel slightly accomplished(lol).

Do I dare attempt the rejet the carb on my own or will I take it to my local chopper shop for that?

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Used to have 2006 S40 http://suzukisavage.com/cgi-bin/YaBB.pl?num=1331666008/0
Gear up like you are going to slide across the pavement. Ride like everyone else is trying to kill you

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