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Im installing slip on mufflers on my 06 1200 Custom Sportster and need to know how to get the stock mufflers off. I have removed the heat shields and all the connecting bolts so the mufflers are loose...but the black crossover pipe is still bolted up and wont budge and both header pipes are still connected. Is there any way to remove the mufflers without taking off the black crossover pipe?
Sandman,
I put a set of SEII's on my 1200 custom last year. All I had to do was loosen the main muffler clamp and the 2 additional bolts that hold the muffler onto the crossover tube. Once this was done I was able to slightly able to lift the back of the muffler to get it to diconnect from the crossover tube and twist back and forth. They came right off. I Installed the SEII's in the same manner.
If the 06 crossover tube is the same as on my O4 you should not even have to touch it. As a matter of fact the only reason that I even loosened up the heat sheilds is to slide them forward slightly to keep the edges from scratching the new pipes as I I had to slightly twist them back and forth when working them on. I also sprayed a little WD 40 on the insided of the muffler neck and also onto the end of the header pipe to keep from scuffing up any of the metal finish.
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