Buell 2002 S3T - Exhaust System

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2-56 2002 Buell S3T: Chassis
EXHAUST SYSTEM 2.27
REMOVAL/DISASSEMBLY
Muffler
NOTE
The muffler may be removed for replacement without remov-
ing the exhaust header.
1. Remove right side fairing lower. See 2.38 FAIRING
LOWERS.
2. See Figure 2-88. Remove bolts, lockwashers and wash-
ers securing muffler to Z-bracket.
3. See Figure 2-89. Remove bolts and locknuts with wash-
ers from header support mount.
4. Loosen screw securing muffler clamp.
5. Remove muffler and muffler clamp. Discard clamp.
6. If necessary, remove muffler support Z-bracket.
a. Remove bolts, locknuts and washers.
b. Remove muffler support Z-bracket.
c. Remove rear muffler mounts and mount spacers
from swingarm mount block.
7. If necessary, remove header support mount.
a. See Figure 2-90. Support motorcycle with jack.
b. Remove bolts, locknuts and washers.
c. Remove nuts and washers securing front muffler
support to voltage regulator bracket and crankcase.
d. Remove header support mount.
Exhaust Header
1. Remove muffler.
2. See Figure 2-91. Loosen the four exhaust header nuts
(20) using SNAP-ON SWIVEL SOCKET (Part No.
PFSX916).
3. Disconnect oxygen sensor at connector [137].
4. See Figure 2-92. Remove exhaust header by swiveling
and lifting exhaust header as shown. Slide exhaust
header from behind frame.
5. See Figure 2-93. Remove exhaust header clamps (22),
exhaust clamp retaining rings (23) and exhaust port gas-
kets (24) from exhaust header.
Figure 2-88. Rear Muffler Mounts
Figure 2-89. Header Support Mount
Figure 2-90. Supporting Motorcycle with Jack
6751
Strap
Washers (2)
Bolt, Gr. 8 (2)
Muffler
b0837x2x
Voltage Regulator
Mount Bracket
Bolt Gr. 8
Header Support
Washer
Washer
Spacer
Metal
Locknut
Header Support
Mount
)
Mount Bolt
Flat Spot Under
Mount Block
Jack
b0887x2x