Help getting exhaust pipe off!
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Joined: Apr 2020
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From: Houston, TX
Help getting exhaust pipe off!
Howdy! Hope everyone is staying safe right now...I am having the hardest time getting the front exhaust off of my 2018 XL1200C. I'm installing forward controls and can't get to the bolts that are holding the peg on the right. I have unscrewed the bolts holding the exhaust pipe in as well as all the heat shields retainers. I am having a hard time prying this sh** off! Any suggestions? It rotates a little bit, but I can't pull it out! It looks like it is attached to a black tube that is also attached to the rear exhaust pipe. Any help would be appreciated!
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Joined: Sep 2017
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From: England
The muffler is attached to a bracket with 2 bolts to support its weight. The header has a balance pipe that connects to the rear header but is only a push fit and held in place by 2 nuts at the exhaust port.
Get a FSM!
After removing the heatshields it should be possible to remove the 2 nuts at the exhaust port and the 2 bolts holding the muffler and remove the exhaust in one piece.
Get a FSM!
After removing the heatshields it should be possible to remove the 2 nuts at the exhaust port and the 2 bolts holding the muffler and remove the exhaust in one piece.
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Joined: Apr 2020
Posts: 52
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From: Houston, TX
The muffler is attached to a bracket with 2 bolts to support its weight. The header has a balance pipe that connects to the rear header but is only a push fit and held in place by 2 nuts at the exhaust port.
Get a FSM!
After removing the heatshields it should be possible to remove the 2 nuts at the exhaust port and the 2 bolts holding the muffler and remove the exhaust in one piece.
Get a FSM!
After removing the heatshields it should be possible to remove the 2 nuts at the exhaust port and the 2 bolts holding the muffler and remove the exhaust in one piece.
Seasoned HDF Member
Joined: Sep 2017
Posts: 12,233
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From: England
The HD OEM Factory Service Manual.
It would actually instruct you to take the exhaust off in two pieces but for what you are doing it isn't necessary. you just need something under it to support its weight. I use a small flat bed bike jack.
It would actually instruct you to take the exhaust off in two pieces but for what you are doing it isn't necessary. you just need something under it to support its weight. I use a small flat bed bike jack.
Last edited by Andy from Sandy; Apr 12, 2020 at 04:20 AM.
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Joined: Apr 2020
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From: Houston, TX
Ah...I think I have the manual somewhere...so are you telling me to put a support under the front exhaust and still try to pry and wiggle it off??
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From: England
Okay I forgot, you need to unplug the O2 sensor connector. It is on the left side of the bike down below the clutch cable boot.
Do you have the heat shields removed? They are held on with jubilee clips. Once you have undone them fully you just straighten them out a little and pull the shield off the pipe and muffler.
After taking the nuts off at the front to release the header support the weight of the muffler on something then remove the two bolts that hold the muffler to the bracket.
Once done the exhaust is free. It should swing out so that header comes away from the interconnect pipe and will come off quite easily.
Do you have the heat shields removed? They are held on with jubilee clips. Once you have undone them fully you just straighten them out a little and pull the shield off the pipe and muffler.
After taking the nuts off at the front to release the header support the weight of the muffler on something then remove the two bolts that hold the muffler to the bracket.
Once done the exhaust is free. It should swing out so that header comes away from the interconnect pipe and will come off quite easily.
Last edited by Andy from Sandy; Apr 12, 2020 at 05:16 AM.
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Joined: Jun 2007
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From: Bedford UK
Welcome to the modern Sporty exhaust system! It's a thing of baffling beauty. My 2011 gave me similar problems, although it is different again to yours. I had to admit defeat and resort to my FSM, but at least I had mine close at hand! It wasn't easy getting mine off, but the book proved essential. Find yours before you go any further as it will make your life easier and help us answer any queries you have.
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From: England
I also have the 2008 bike so is the same as your 2011.
I will admit if the exhaust is in pieces then the manual is essential for the first time but for the job in hand the muffler doesn't need separating from the header and can be removed in one piece.
I have done this a couple of times on the 2008 to carry out a couple of jobs.
I will admit if the exhaust is in pieces then the manual is essential for the first time but for the job in hand the muffler doesn't need separating from the header and can be removed in one piece.
I have done this a couple of times on the 2008 to carry out a couple of jobs.
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Seasoned HDF Member
Joined: Sep 2017
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From: England
I know what you mean with the jigsaw puzzle and the way to get it all off and on when in bits.
I restored Cindy's trike to stock mufflers and had the bracket / interconnect pipe off as it had to be modified and painted.
I restored Cindy's trike to stock mufflers and had the bracket / interconnect pipe off as it had to be modified and painted.