Warning - Buell S1 Lightning Workshop Manual

REMOVAL/DISASSEMBLY
Muffler
1. See Figure 2-58. Remove bolts (2), locknuts (9) and
washers (6) from rear muffler supports (19).
2. Remove bolt (3) and locknut (9) from muffler support (15).
3. Loosen muffler clamp (14).
4. Loosen screw (1) on header tiebar (26).
5. Remove muffler (13) and muffler clamp. Discard clamp.
6. Remove muffler/header supports (15, 19) as follows:
a. Remove bolts (4), locknuts (9) and washers (21).
b. Remove rear muffler mounts (24) and mount spac-
ers (20).
c. Remove bolts (5), locknuts (10) and washers (7).
d. Remove muffler support (15). Remove front muffler
mounts (25) and mount spacer.
Exhaust Header
1. See Figure 2-58. Remove muffler as described above.
2. Remove screw (1), locknut (11) and washers (27) from
header tiebar (26).
3. Using a SNAP-ON SWIVEL SOCKET (Part No.
PFSX916), remove nuts (8) from front and rear cylinder
head exhaust studs.
4. Remove exhaust header clamps (18), exhaust clamp
retaining rings (17) and exhaust port gaskets (16).
5. Remove exhaust header (12).
6. Remove heat shield clamps (23) and heat shield (22)
from exhaust header.
ASSEMBLY/INSTALLATION
Muffler
1. See Figure 2-58. If removed, install exhaust header (12).
2. If removed, install muffler/header supports (15, 19).
a. Hold rear muffler mounts (24), mount spacers (20)
and muffler supports (19) in place. Fasten with bolts
(4), locknuts (9), washers (21). Tighten to 12-15 ft-
lbs (16.3-20.3 Nm).
b. Fasten muffler support (15) to crankcase with bolts
(5), washers (7) and locknuts (10). Tighten to 30-33
ft-lbs (40.7-44.7 Nm).
c. Install front muffler mounts (25) and mount spacer.
2-50
EXHAUST SYSTEM
3. Coat inside of muffler inlet with PERMATEX ULTRA-
COPPER HIGH TEMP RTV SILICON GASKET material.
4. Place a new muffler clamp (14) over slotted end of muf-
fler. Place muffler and clamp on end of exhaust header.
Loosely tighten clamp.
If necessary, use a fiber hammer to fit muffler on header.
5. Install bolt (3) and locknut (9). Tighten to 22-25 ft-lbs
(29.8-33.9 Nm).
Before tightening muffler hardware, position muffler to
provide adequate clearance from rear shock absorber
and side stand spring post. Failure to provide adequate
clearance may cause personal injury during motorcycle
operation.
6. Install rear mounting bolts (2), washers (6), and locknuts
(9). Tighten to 22-25 ft-lbs (29.8-33.9 Nm).
7. Tighten muffler clamp (13) to 50-55 ft-lbs (67.8-74.6 Nm).
Exhaust Header
1. See
exhaust clamp retaining rings (17), exhaust header
clamps (18), and nuts (8). Loosely tighten nuts with
SNAP-ON SWIVEL SOCKET (Part No. PFSX916).
2. Install screw (1) with washers (27) and locknut (11).
Tighten to 5-7 ft-lbs (6.8-9.5 Nm).
3. Place a new muffler clamp (14) over slotted end of muf-
fler. Place muffler and clamp on end of exhaust header
(20). Loosely tighten clamp.
4. Tighten manifold nuts (8) to 6-8 ft-lbs (8.1-10.8 Nm).
5. Tighten muffler clamp (13) to 50-55 ft-lbs (67.8-74.6 Nm).
6. If removed, install heat shield (22) with heat shield
clamps (23).
NOTE
1

WARNING

Figure 2-58. Install new exhaust port gaskets (16),