1. | Remove saddlebags per the service manual. | |
2. | See the service manual. Remove the original equipment (OE) exhaust system. Save exhaust flanges ( Figure 1 , item 3) and mounting hardware for later installation. | |
3. | See the service manual. Remove oxygen (O2) sensors. Save for installation. | |
4. | See Figure 2. Remove exhaust bracket (9) at the rear of transmission case (5). Discard bracket and fasteners. | |
5. | See Figure 1. Remove pipe shields (6 and 7) and clamps (4) from front and rear head pipes. Save pipe shields and clamps for later installation. | |
6. | Remove collector shield (1). Remove and save clamps (5). Discard collector shield. | |
7. | See the service manual. Install O2 sensors in new head pipe. Tighten to 16–19 N·m (12–14 ft-lbs). | |
8. | Apply Anti-Seize Lubricant to O2 sensor plugs (10). Install seal rings (11) and O2 sensor plugs into ARF data monitoring ports. Tighten to 40–60 N·m (30–44 ft-lbs). | |
9. | See the service manual. Loosely install new head pipe (13). | |
10. | See Figure 1. Loosely install transmission exhaust bracket bolt (2) and nut (9). | |
11. | See the service manual and Figure 2. Loosely install new cross-under exhaust pipe (10) and clamp (6). | |
12. | Verify that the holes of the exhaust pipe bracket align with the mounting holes in the transmission (5). Loosely install new flange screws (9). | |
13. | See Figure 1. Tighten exhaust manifold nuts (8) to 11.3–13.6 N·m (100–120 in-lbs). | |
14. | Tighten the transmission exhaust bracket bolt (2) and nut (9) to 27–34 N·m (20–25 ft-lbs). | |
15. | Check the cross-under exhaust pipe alignment. Verify that the exhaust pipe is not bound or stressed. | |
16. | See Figure 2. Tighten flange screws (9) to 9.5–14.9 N·m (84–132 in-lbs). | |
17. | Tighten the cross-under exhaust pipe clamp (6) to 47.5 N·m (35 ft-lbs). | |
18. | Install new muffler clamps onto mufflers and slide onto headpipes. | |
19. | See the service manual. Install mufflers (3). | |
20. | See the service manual. Route and connect O2 sensor wiring. | |
21. | See Figure 1. Install collector shield (1) using worm drive clamps (5) and (4) removed earlier. Tighten to 2.2–4.5 N·m (20–40 in-lbs). | |
22. | See Figure 2. Install cross-under exhaust pipe shield (2) using worm drive clamps (1) removed earlier. Tighten to 2.2–4.5 N·m (20–40 in-lbs). | |
23. | See Figure 1. Install pipe shields (6 and 7) using worm drive clamps (4) removed earlier. Tighten to 2.2–4.5 N·m (20–40 in-lbs). | |
NOTICE Wipe all fingerprints off of exhaust system components after installation and before starting engine. Oil from hands can leave permanent marks on exhaust system finish. (00346a) | ||
24. | Wipe exhaust system clean. |
1 | Collector shield |
2 | Carriage bolt |
3 | Clamp ring (2) |
4 | Worm drive clamp (5) |
5 | Worm drive clamp (2) |
6 | Pipe shield assembly |
7 | Pipe shield assembly |
8 | Flange nut (4) |
9 | Flange nut |
10 | Oxygen sensor plug (2) |
11 | Seal ring (2) |
12 | Exhaust support bracket |
13 | Exhaust pipe |
1 | Worm drive clamp (2) |
2 | Pipe shield, cross-under exhaust pipe |
3 | Muffler (2) |
4 | Muffler mounting bracket (2) |
5 | Transmission |
6 | Muffler clamp |
7 | Muffler clamp (2) |
8 | Screw (4) |
9 | Flange screw (2) |
10 | Cross-under exhaust pipe |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Pipe shield, left (chrome) Pipe shield, left (black) | 65400156 65400229 |
2 | Muffler assembly, disc style (chrome) (2) Muffler kit, end cap style (left/right, chrome) Muffler kit, end cap style (left/right, black) | 64900203 64900397 64900398 |
3 | Muffler clamp | 65900009 |
4 | Muffler clamp (2) | 65900010 |
5 | Worm drive clamp | 9956 |
6 | Collector shield (chrome) Collector shield (black) | 65400164 65400228 |
7 | Oxygen sensor plug (2) | 65835-09 |
8 | Screw, flange | 3563 |
9 | Seal ring | 27714-06 |
10 | Exhaust pipe, left | 64800020 |
11 | Exhaust pipe | Not sold separately |
12 | Pipe shield kit (black) | 64981-09 |