Service Manual

ENGINE TOP END 5-19
Muffler/Exhaust Pipe Installation
Muffler/Exhaust Pipe Removal
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Loosen the clamp nut [A].
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Remove the bolt [B] on the muffler bracket and take off the muffler.
•
Unscrew the exhaust pipe flange nuts [A], and remove the exhaust
pipe [B] with pipe cover [C]. Use a penetrating oil if necessary to
break threads loose.
•
Remove the gaskets.
•
Unscrew the hook nut [D], separate the exhaust pipe and pipe cover.
•
Do not use unnecessary force on the exhaust pipes when removing
the muffler assembly, or they could become damaged or distored.
Muffler/Exhaust Pipe Installation
•
Clean the exhaust pipe flanges and the exhaust port gasket surfaces
and install a new gaskets each time the muffler installed.
•
Install the gasket.
•
To prevent mis-threading, finger tight the flange nuts first. Next tighten
the hook nut.
•
Tighten the nuts.
Torque - Exhaust Pipe Flange Nuts: 15 N 1 m (1.5 kgf 1 m, 11 ft
1 lb)
•
Install the muffler.
•
After installation, thoroughly warm up the engine, wait until the engine
cools down and retighten the bolts and nuts.
Inspection
•
Inspect the exhaust pipe or muffler for dents, cracks, rust and holes.
If the exhaust pipe or muffler is damaged, it should be replaced for
best performance and least noise.
•
Check the muffler for distortion and/or loose internal components.
Loss of power could develop if loose internal muffler components
restrict exhaust flow.
•
Check for breaks in the seams and check weld at the junction of the
exhaust pipes and muffler.
•
Tap the muffler with a plastic hammer to decarbonize.