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General Category >> Rubber Side Down! >> S40 muffler removal
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Message started by wingdwolf56 on 10/20/05 at 13:41:15

Title: S40 muffler removal
Post by wingdwolf56 on 10/20/05 at 13:41:15

Will someone please detail an S40 stock muffler removal? I'm lost!

Title: Re: S40 muffler removal
Post by slavy on 10/20/05 at 19:43:07

Remove the 2 right side footpeg bracket nuts.
Remove the 2 bolts that hold the header to the cyl. head
Remove the 2 nuts that hold the muffler to the muffler bracket /they are between the muffler and the rear wheel/
Remove the whole pipe assy
Remove the heat shield - 2 philips screws and a bolt for the heat shield clamp
Losen the muffler clamp and spray liberaly WD40 in the connection between the header and the muffler.
Twist, turn and pull on the header and the muffler untill
they separate.
You can try to just take apart the heat shield clamp and losen the muffler clamp.After that You take off the 2 nuts that hold the muffler to the muffler bracket .Pull apart the muffler from the header. But in a long run it will be easier to go the first road. Seems more work, but it is easier.

Title: Re: S40 muffler removal
Post by wingdwolf56 on 10/21/05 at 11:55:25

Thanks..I kinda figured I'd have to remove the whole thing. I was hoping to avoid that...but..oh well...Thanks Again!

Title: Re: S40 muffler removal
Post by vroom1776 on 10/21/05 at 13:36:03

I did get my muffler off without removing the whole exhaust assembly, but I needed help. My frieed pulled on it, out and back, while I held the bike in place, after I loosened the appropriate bolts & nuts. No damage.

Now if someone would figure out an easy way to get the tank on and off... what a PITA! >:( On my other two bikes, GT removal & unremoval is very easy...

Title: Re: S40 muffler removal
Post by barb36jack31 on 10/21/05 at 18:39:29

For Slavy - Thanks for the complete info re removing the muffler on the S40. Very clear and to the point. Any recommendations for a replacement? Mac, SuperTrapp?

I am looking for a solid, low thumper sound rather than a LOUD pipe. I have used SuperTrapp in the past on both a Suzuki DR 250 and Kawasaki KLR 650. Loved them both.

Jack H.