2-80 2005 Buell Firebolt: Chassis
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ASSEMBLY/INSTALLATION
Exhaust Header
1. See Figure 2-110. Install exhaust ring (4), retaining ring
(5) and new port gasket (6).
2. Install exhaust header (2). Tighten mounting fasteners
(3) to 72-96 in-lbs (8-11 Nm).
NOTE
Tighten header nuts gradually, alternating between studs to
insure that exhaust rings are flush with engine.
3. Install oxygen sensor. See 4.33 OXYGEN SENSOR.
4. Rotate engine up. See 3.3 ENGINE ROTATION FOR
SERVICE.
Rear Muffler Bracket
1. See Figure 2-109. Slide rear muffler bracket (9) over oil
lines.
2. Install rear muffler bracket fasteners (10) and tighten to
32-36 ft-lbs (43-49 Nm).
3. Install oil lines to swingarm. See 3.9 OIL HOSE ROUT-
ING AND OIL RESERVOIR.
4. Fill swingarm/oil tank with 2.5 quarts (3.3 liters) oil. See
1.6 ENGINE LUBRICATION SYSTEM.
5. Install muffler.
NOTE
For details on removal of components on XB12R with interac-
tive exhaust systems, see REMOVAL under 7.6 INTERAC-
TIVE EXHAUST SYSTEM(XB12 MODELS ONLY).
Front Muffler Mount
1. See Figure 2-109. Install front muffler mount bushings
(8).
2. Install new strap on front muffler mount (6).
3. Install front muffler mount fastener (7) loosely. Do not
tighten.
4. Install muffler.
Muffler and Straps
NOTE
Torca muffler clamps have eliminated the need for silicone or
graphite tape during assembly. To ensure sealing integrity of
muffler clamps and prevent the possibility of leakage, Buell
recommends that muffler clamp assemblies be discarded and
replaced each time they are removed.
1. Install muffler and new Torca clamp onto header.
NOTE
If necessary, use a fiber hammer to fit muffler on header.
11WARNING1WARNING
Never reuse front muffler strap. Always replace front
muffler strap with a new strap when removed from sys-
tem.
2. See Figure 2-109. Loosely install new front and rear
muffler straps (2, 4).
11WARNING1WARNING
Muffler straps must be tightened in steps to keep from
over tightening or muffler will be crushed.
11WARNING1WARNING
Always ensure that straps do not contact the chin fairing
or the idler pulley assembly.
3. Tighten front strap fastener and alternately tighten rear
muffler strap fasteners evenly till fasteners are tightened
to:
a. Front: Tighten around the muffler until snug.
b. Rear: 48-60 in-lbs (5-7 Nm).
c. Front muffler mount: 16-18 ft-lbs (21.7-24.4 Nm).
d. Front: 108-120 in-lbs (12-14 Nm). Back off fastener
two full turns and then retighten to 108-120 in-lbs
(12-14 Nm).
NOTE
On the front muffler mount fastener, torque is applied to the
head and not to the nut.
4. See Figure 2-110. Tighten the Torca clamp (1) to 28-
30 ft-lbs (38-40.6Nm).
5. Install idler pulley. See 6.6 DRIVE BELT SYSTEM.
6. Install front sprocket cover. See 2.30 SPROCKET
COVER.
7. Install chin fairing. See 2.33 CHIN FAIRING.
Figure 2-110. Exhaust Header
b0973a2x
1
1. Torca clamp
2. Header
3. Header mount fastener
4. Exhaust ring
5. Exhaust retaining ring
6. Exhaust port gasket
2
4
5
6
3
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