Exhaust System - Buell 2002 X1 Handbook

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EXHAUST SYSTEM

REMOVAL/DISASSEMBLY
Muffler
NOTE
The muffler may be removed for replacement without remov-
ing the exhaust header.
1. Remove chin fairing. See
2. See Figure 2-104. Remove two bolts, washers and lock-
nuts securing rear of muffler to Z-bracket.
3. See Figure 2-105. Remove lower bolt (Gr. 8), metal lock-
nut, washers and spacer from header support mount at
the front of the muffler.
4. Loosen screw securing muffler clamp.
5. Remove muffler and muffler clamp. Discard clamp.
6. If necessary, remove muffler support Z-bracket from
mount block.
a. Remove bolts, locknuts and washers.
b. Remove muffler support Z-bracket.
c. Remove rear muffler mounts and mount spacers
from swingarm mount block.
7. If necessary, remove header support mount.
a. See Figure 2-106. Support motorcycle with jack.
b. Remove bolts, locknuts and washers.
c. Remove nuts and washers securing front muffler
support to voltage regulator bracket and crankcase.
d. Remove muffler support. Remove front muffler
mounts and mount spacer.
Exhaust Header
1. Remove muffler.
2. Remove any restrictive cable straps on oxygen sensor
wiring. Detach oxygen sensor connector [137].
3. See Figure 2-107. Loosen the four exhaust header nuts
(20) using SNAP-ON SWIVEL SOCKET (Part No.
PFSX916).
4. See Figure 2-108. Remove exhaust header by swiveling
and lifting exhaust header as shown. Slide exhaust
header from behind frame.
5. See Figure 2-107. Remove exhaust header clamps (22),
exhaust clamp retaining rings (23) and exhaust port gas-
kets (24) from exhaust header.
2002 Buell X1: Chassis
2.34 CHIN FAIRING.
6751
Bolt, Gr. 8 (2)
Muffler
Washers (2)
Figure 2-104. Rear Muffler Mounts
b0837x2x
Voltage Regulator
Mount Bracket
Metal
Locknut
Washer
Spacer
Figure 2-105. Header Support Mount
b0887x2x
Jack
Figure 2-106. Supporting Motorcycle with Jack
2.28
Strap
Header Support
Mount Bolt
)
Header Support
Mount
Bolt Gr. 8
Washer
Flat Spot Under
Mount Block
2-65