Exhaust System - Buell P3 2003 Service Manual

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EXHAUST SYSTEM

MUFFLER REMOVAL
CAUTION
To prevent damage to muffler, secure muffler before
removing rear muffler strap.
1. See Figure 2-101. Remove fasteners, washers, spacers
and brackets on rear muffler strap.
2. Remove exhaust header fasteners (13).
3. Remove front muffler mounting fastener, nut, and washer
(4, 7, 12).
4. Remove exhaust header.
5. Remove retaining ring (2).
6. Remove exhaust header clamp (3).
7. Remove and discard exhaust port gasket (1).
MUFFLER INSTALLATION
1. See Figure 2-101. Install new bushings and spacer onto
front muffler support hole (8, 17, 11).
2. Install header clamp onto exhaust (3).
3. Install retaining ring oriented 90° from exhaust studs (2).
NOTE
Retaining ring may crack if not oriented as stated in step 3.
4. Install new exhaust port gasket (1).
5. Position muffler on motor. Hand tighten nuts (13).
6. Slide muffler over bushings on front mount.
7. Hand thread bolt washer and nut to front muffler support.
8. Install rear muffler strap (15).
NOTE
A rubber mallet may be used to tap the muffler strap into muf-
fler notches.
9. Install right side muffler spacers (9), brackets (16) and
fasteners (5).
10. Install left side muffler spacers, brackets and fasteners.
11. Hand tighten fasteners on rear muffler strap bolts (5,6).
12. Tighten lower, then upper header nuts to 72-96 in-lbs (8-
11 Nm).
13. Tighten rear strap screws (5, 6) to 22-25 ft-lbs (30-34
Nm).
14. Tighten front muffler bolts (4) to 22-25 ft-lbs (30-34 Nm).
CAUTION
Use care when performing service procedures and avoid
scratching the frame and/or painted parts. Failure to do
so may result in corrosion of parts.
2.20
2003 Buell P3: Chassis 2-57