4.16EXHAUST SYSTEM
REMOVAL: ALL BUT FXDF
NOTE
If removing exhaust as an assembly and not removing mufflers,
skip muffler removal steps.
1. Remove seat.
2. See Figure 4-60. Disconnect rear O2 sensor connector
[137]. Note wire routing for proper installation.
3. See Figure 4-61. Open front electrical caddy cover and
disconnect front O2 sensor connector [138] (1). Remove
connector housing from caddy.
4. See Figure 4-62. On models with an active exhaust
module, remove active exhaust cable (1):
a. Remove cable (1) and retainer (2) from exhaust pipe.
b. Remove ferrule (3) from bellcrank (4).
5. See Figure 4-63. Remove muffler support bracket nuts
(29) from bolts (30). Remove muffler support bracket (28).
6. Loosen locknuts (17) on muffler clamps (19) to exhaust
pipes. Remove mufflers (16, 27).
7. Loosen or remove heat shields (1, 8) by opening worm
drive clamps (2).
8. Remove flange nuts (35) from front and rear cylinder head
exhaust studs.
9. Remove locknut (3) and bolt (41) attaching front exhaust
pipe clamp (4) to front exhaust bracket (40).
10. Remove bolt (13), acorn nut (15) and washer (14)
attaching rear exhaust pipe clamp (10) to rear exhaust
bracket (23). Remove bracket (44) if equipped.
11. Remove exhaust system as an assembly.
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