Exhaust System - Buell 2003XB9S Service Manual

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EXHAUST SYSTEM

REMOVAL/DISASSEMBLY
Muffler
1. Remove chin fairing. See
2. Remove front sprocket cover. See
COVER.
3. Remove idler pulley. See
1.10 DRIVE BELT.
4. See Figure 2-99. Loosen front muffler mount fastener (7)
but do not remove.
5. Remove front and rear muffler straps.
Front: Remove front muffler strap fastener (5). Front
strap will not be removed.
Rear: Alternately loosen rear strap fasteners (1) and
remove straps (2).
6. See Figure 2-100. Loosen Torca clamp (1) and remove
muffler.
NOTE
The muffler may be removed for replacement without remov-
ing the exhaust header.
Front Muffler Mount
1. Remove muffler. See Muffler
1
2
*
Jacking point symbol shown
on both sides of muffler.
1. Rear muffler strap fastener (2)
2. Rear muffler strap (2)
3. Muffler
4. Front muffler strap
5. Front muffler strap fastener
2.34 CHIN FAIRING.
2.31 SPROCKET
DRIVE BELT REMOVAL
in this section.
10
*
3
Figure 2-99. Muffler Assembly
2. See Figure 2-99.
(7).
3. Remove strap (4) from front muffler mount (6).
4. Remove front muffler mount bushings (8) by punching
out with suitable tool.
Rear Muffler Bracket
1. Remove muffler. See
in
2. Drain oil. See Draining Oil
TION SYSTEM.
3. Remove oil lines from swingarm. See
ROUTING AND OIL RESERVOIR.
4. See Figure 2-99.
(10).
5. Slide oil lines from rear muffler bracket and remove rear
muffler bracket (9).
Exhaust Header
1. Rotate engine down. See
SERVICE.
2. Remove oxygen sensor. See
3. See Figure 2-100.
removing mounting fasteners (3).
4. Remove exhaust ring (4), retaining ring (5) and port gas-
ket (6).
9
*
6. Front muffler mount
7. Front strap fastener
8. Front muffler mount bushings
9. Rear muffler bracket
10. Rear muffler bracket fasteners (2)
Remove front muffler mount fastener
Muffler in this section.
in 1.6 ENGINE LUBRICA-
3.9 OIL HOSE
Remove rear muffler bracket fasteners
3.3 ENGINE ROTATION FOR
4.32 OXYGEN SENSOR.
Remove exhaust header (2) by
8
7
5
6
4
2003 Buell XB9S: Chassis
2.29
b0957x2x
2-73