Buell XB9R 2003, Service Manual, Page: 172 / 566

2003 Buell XB9R: Chassis 2-67
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ASSEMBLY/INSTALLATION
Exhaust Header
1. See Figure 2-99. Install exhaust ring (4), retaining ring
(5) and new port gasket (6).
2. Install exhaust header (2). Tighten mounting fasteners
(3) to 72-96 in-lbs (8-11 Nm).
NOTE
Tighten header nuts gradually, alternating between studs to
insure that exhaust rings are flush with engine.
3. Install oxygen sensor. See 4.32 OXYGEN SENSOR .
4. Rotate engine up. See 3.3 ENGINE ROTATION FOR
SERVICE .
Rear Muffler Mounting Block
1. See Figure 2-98. Slide rear muffler mounting block (9)
over oil lines.
2. Install rear muffler mounting block fasteners (10) and
tighten to 32-36 ft-lbs (43-49 Nm).
3. Install oil lines to swingarm. See 3.9 OIL HOSE ROUT-
ING AND OIL RESERVOIR.
4. Fill swingarm/oil tank with 2.5 quarts (3.3 liters) oil. See
Draining Oil in 1.5 ENGINE LUBRICATION SYSTEM .
5. Install muffler. See Muffler in this section.
Front Muffler Mounting Block
1. See Figure 2-98. Install front mounting block bushings
(8).
2. Install strap on front muffler mounting block (4).
3. Install front muffler mounting block fastener (7) loosely.
Do not tighten.
4. Install muffler. See Muffler in this section.
Muffler and Straps
NOTE
Torca muffler clamps have eliminated the need for silicone or
graphite tape during assembly. To ensure sealing integrity of
muffler clamps and prevent the possibility of leakage, Buell
recommends that muffler clamp assemblies be discarded and
replaced each time they are removed.
1. Install muffler and new Torca clamp onto header.
NOTE
If necessary, use a fiber hammer to fit muffler on header.
2. See Figure 2-98. Loosely install front and rear muffler
straps (2, 4).
1 1
WARNING
1
WARNING
Muffler straps must be tightened in steps to keep from
over tightening or muffler will be crushed.
3. Tighten front strap fastener and alternately tighten rear
muffler strap fasteners evenly till fasteners are tightened
to:
Front: 108-120 in-lbs (12-14 Nm).
Rear: 48-60 in-lbs (5-7 Nm).
4. See Figure 2-98. Tighten front muffler mounting block
fastener (7) to 22-25 ft-lbs (30-34 Nm).
5. See Figure 2-99. Tighten the Torca clamp (1) to 40-45 ft-
lbs (54-61 Nm).
6. Install idler pulley. See DRIVE BELT REMOVAL in 1.9
DRIVE BELT SYSTEM .
7. Install front sprocket cover. See 2.30 SPROCKET
COVER .
8. Install chin fairing. See 2.33 CHIN FAIRING .
Figure 2-99. Exhaust Header
b0973x2x
5
3
4
6
1
2
1. Torca clamp
2. Header
3. Header mount fastener
4. Exhaust ring
5. Exhaust retaining ring
6. Exhaust port gasket