Repair Engine and Upper Machine Components
wc_tx001546gb.fm 57
4.16 Muffler (pre-2009 BS Models)
See Graphic: wc_gr001314rm
Recommended Tools
Ratchet wrench
Torque wrench
Hex key: 5 mm
Hex key or hex socket: 6 mm
Socket: 19 mm (3/4”)
Loctite 243 (blue)
Carbon deposits can form in the muffler (d) and in the cylinder exhaust
port. If allowed to accumulate, they will gradually restrict the exhaust
passages, resulting in poor engine performance and hard starting.
Factors contributing to this problem include:
• Too much oil in the fuel mixture
• Dirty air filter causing the engine to run rich
• Excessive engine idling
• Dirty carburetor
4.16.1 Remove the two hex head cap screws (a) holding the muffler guard (b)
to the muffler (d). When reinstalling the muffler guard, apply Loctite
243 and torque the screws to 35 Nm (25 ft.lbs.).
4.16.2 Remove the two socket head cap screws (f) holding the muffler and
the muffler guard to the engine cylinder. When reinstalling the muffler
and the muffler guard, apply Loctite 243 and torque the screws to 23
Nm (17 ft.lbs.).
4.16.3 Remove the two socket head cap screws (c) located inside the muffler.
4.16.4 Remove the muffler.
4.16.5 Slowly pull the starter rope until the piston is at the top of its stroke and
is covering the exhaust port. This prevents dirt from entering the
engine cylinder.
4.16.6 Remove any carbon deposits on the engine exhaust port with a blunt
scraper.
4.16.7 Replace the silencer gasket (e).
4.16.8 Soak the muffler in carburetor cleaner or a similar cleaning solution for
several hours.
4.16.9 Drain the muffler and blow it dry.
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