Buell 2003XB9S Service Manual page 177

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ASSEMBLY/INSTALLATION
Exhaust Header
1. See Figure 2-100. Install exhaust ring (4), retaining ring
(5) and new port gasket (6).
2. Install exhaust header (2). Tighten mounting fasteners
(3) to 72-96 in-lbs (8-11 Nm).
NOTE
Tighten header nuts gradually, alternating between studs to
insure that exhaust rings are flush with engine.
3. Install oxygen sensor. See
4. Rotate engine up. See
SERVICE.
Rear Muffler Mounting Block
1. See Figure 2-99. Slide rear muffler bracket (9) over oil
lines.
2. Install rear muffler mounting bracket fasteners (10) and
tighten to 32-36 ft-lbs (43-49 Nm).
3. Install oil lines to swingarm. See
ING AND OIL RESERVOIR.
4. Fill swingarm/oil tank with 2.5 quarts (3.3 liters) oil. See
Draining Oil in 1.6 ENGINE LUBRICATION
5. Install muffler. See Muffler
Front Muffler Mount
1. See Figure 2-99. Install front muffler mount bushings (8).
2. Install strap on front muffler mount (6).
3. Install front muffler mount fastener (7) loosely. Do not
tighten.
4. Install muffler. See Muffler
Muffler and Straps
NOTE
Torca muffler clamps have eliminated the need for silicone or
graphite tape during assembly. To ensure sealing integrity of
muffler clamps and prevent the possibility of leakage, Buell
recommends that muffler clamp assemblies be discarded and
replaced each time they are removed.
1. Install muffler and new Torca clamp onto header.
NOTE
If necessary, use a fiber hammer to fit muffler on header.
2. See Figure 2-99. Loosely install front and rear muffler
straps (2, 4).
2-74 2003 Buell XB9S: Chassis
4.32 OXYGEN SENSOR.
3.3 ENGINE ROTATION FOR
3.9 OIL HOSE ROUT-
SYSTEM.
in this section.
in this section.
11 1
WARNING
Muffler straps must be tightened in steps to keep from
over tightening or muffler will be crushed.
11 1
WARNING
Always ensure that straps do not contact the chin fairing
or the idler pulley assembly.
3. Tighten front strap fastener and alternately tighten rear
muffler strap fasteners evenly till fasteners are tightened
to:
Front: 108-120 in-lbs (12-14 Nm).
Rear: 48-60 in-lbs (5-7 Nm).
4. See Figure 2-99. Tighten front muffler mount fastener (7)
to 22-25 ft-lbs (30-34 Nm).
5. See Figure 2-100. Tighten the Torca clamp (1) to 40-
45 ft-lbs (54-61 Nm).
6. Install idler pulley. See
DRIVE BELT.
7. Install front sprocket cover. See
COVER.
8. Install chin fairing. See 2.34 CHIN
b0973x2x
3
5
4
1. Torca clamp
2. Header
3. Header mount fastener
4. Exhaust ring
5. Exhaust retaining ring
6. Exhaust port gasket
Figure 2-100. Exhaust Header
WARNING
WARNING
DRIVE BELT REMOVAL in
2.31 SPROCKET
FAIRING.
6
2
1
1.10