User Manual Q&AAnswer
Jan 21, 2025 - 05:20 AM
To remove the stock exhaust system from your motorcycle, follow these steps:
1. Before starting, make sure to refer to your motorcycle's owner's manual for torque specifications and follow safety precautions. Ensure that the motorcycle is properly secured to prevent it from falling and that it is not hot to prevent burning.
2. It is recommended to use penetrating oil on all nuts, bolts, and slip joints to ease the removal of the stock exhaust system.
3. Using an 8mm allen wrench, locate and loosen the two bolts holding the right side floorboard to gain access and make the removal and installation easier.
4. If your motorcycle is equipped with O2 sensors, follow steps 5, 6, 7, and 8. If it does not have O2 sensors, you can skip these steps.
5. Remove the plastic side covers (left first, then right) using a 5mm allen wrench. Remove the allen flange bolt and save it for re-use. Carefully pull the cover out.
6. Remove the bolt holding the right side cover from the frame using an 8mm socket or nut driver. This bolt is visible once the left side cover has been removed.
7. Now, using the 5mm allen wrench, remove the right side cover and gently pull it out.
8. Locate the rear O2 sensor, disengage it from the tab, and remove it from the stock assembly using a 14mm wrench. The rear sensor harness is located behind the right side cover. The rear sensor is too short to reach the new exhaust system, so it will need to be re-routed to reach the O2 bung on the new system. Disconnect the Oxygen sensors from the harness and save them for re-use.
9. Using an 8mm allen wrench, locate and remove the exhaust port allen nuts and save them as they will be re-used with your new exhaust system. Inspect the exhaust port allen nuts and replace them if damaged or worn.
10. Remove the allen bolts holding the rear muffler to the mounting bracket. Some assistance may be required.
11. Lift the muffler up to release it from the locating hole of the mounting bracket. Some assistance may be required to prevent scratches or damages.
12. Inspect the condition of the exhaust gaskets and replace them if worn or damaged.
13. Remove the two bolts that hold the stock mounting bracket in place to the frame using an 8mm allen wrench. This bracket will be removed and replaced with a new mounting bracket (supplied).
14. Remove the rear brake hose clamp from the exhaust mounting bracket.
15. The stock mounting bracket holds the rear brake hose with a looped wire welded to the mounting bracket. There are two ways to remove the stock bracket. Step number 16 is easier and faster, while steps 17, 18, 19, and 20 require the brake system to be bled, or the braking system will not work.
16. With large wire cutters or a wheel air grinder, cut a section of the loop wire to slide the hose out of the loop mounting bracket. If you decide to follow the longer route, it is recommended that the installer knows how to adjust the braking system, or serious injuries or even death may occur. Refer to the manufacturer's user manual for proper bleeding of the braking system.
17. Remove the brake hose banjo bolt from the rear caliper. Have some rags available as some brake fluid will spill out.
18. Slide the hose out of the loop mounting bracket.
19. Inspect the condition of the sealing washers on the banjo bolt and replace them if damaged or worn.
20. Now, reconnect the brake hose to the caliper, using the manufacturer-recommended guidelines for torque, and bleed the system according to manufacturer specifications.
Note: Always use good and safe practices when removing and installing your new exhaust system to prevent injuries. This includes wearing safety glasses and gloves. Make sure the gloves are not abrasive to prevent damage or scratching of parts. Always secure the motorcycle before any work is done.
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