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Muffler Removal

Discussion in 'XJ Technical Chat' started by 44Dave, May 5, 2013.

  1. 44Dave

    44Dave Member

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    So I'm replacing the rear shocks, and it looks like I need to take the right muffler off to get clearance for that last bolt to come out. Can't get the stupid muffler off.
    I've freed the bracket by the foot peg, and loosened that compression/hose clamp thing where it joins the pipe, but it still won't come off. Did I miss something? Is there a trick to it? Or do I just need to pull really hard?
     
  2. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Pull, twist, wiggle. PULL, twist, wiggle.

    (Make sure you undid the muffler clamp and not the heat shield clamp.)

    Don't get too medieval on it or you'll wreck the gasket.
     
  3. 44Dave

    44Dave Member

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    OK, I'll give it another shot tonight!
     
  4. biggs500

    biggs500 Active Member

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    Try some Kroil where the muffler joins the collector too.
     
  5. 44Dave

    44Dave Member

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    So anyway, thought I would share how this went down.
    Turns out it was way easier than I thought at first. I simply removed the shock from the other side, and then loosened the bottom bolt on the problem side enough that I could remove the top stud, and the wheel/side arm lowered down, lowering the bolt just enough that I could remove it without the muffler getting in the way. Installation of the new shocks went in reverse.

    Speaking of, I'm a little leary that I haven't installed the new shocks correctly. I have the Prog4ressive suspension 412 series shocks, what like a lot of people seem to use around here. They came with new washer/spacers and I have some left over after installation (which is never a good sign). I'm thinkin I need to take them off again and see where I should put them. The problem is that I didn't have very many of them to take off from the old shocks so I'm not sure where all they go.
    I also realized that I didn't use that little packet of grease that came with the new shocks. Is that supposed to go on the mounting studs to keep the rubber bushing lubridated? Or on the sides of the rubber bushing so they don't start turning? What's the best application for that?
     
  6. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    The shocks come with a whole assortment of bushings/spacers; having a few left over is expected since you only use the ones that apply to your bike.

    I believe the little packet of grease is for the preload adjuster cams. Mine is labeled as such.
     
  7. 44Dave

    44Dave Member

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    Yeah, I figured out the bushing barrel spacers pretty quick, I'm talking more about the flat washers. Are they protecting anything or are they just a spacer kind of thing as well? If they're just a spacer I don't think I really need them; I'm well clear of hitting anything during travel. I just wanted to make sure those washers weren't there to take the friction off the rubber part of the bushings.
     
  8. 44Dave

    44Dave Member

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    I just went back to using the Yamaha hardware instead of the new stuff.
    Anyway, I was happy to feel the difference that these new shocks made. The bike doens't bounce up and down when I get on it now. Makes me want to do the front forks now...
     

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