b. Examine the flange for distortion or other damage;
the flange must be flat to fit properly onto the exhaust
studs. Distortions may be flattened out, but make sure
the edges or holes in the flange are not deformed
when straightening it. Replace a damaged or bent
flange.
c. Check the fit of the flange on the cylinder head studs
before installing it onto the pipe.
d. Clean the end of the pipe to remove all rust and other
debris. If reinstalling a used flange, clean the inside
of the flange thoroughly.
e. Slide the flange on the exhaust pipe so the shoulder
on the flange faces toward the snap ring groove. In-
stall a new snap ring and check its fit; it must be se-
cure in its groove.
f. Repeat for the other exhaust pipe and flange, if re-
quired.
5. Replace worn or damaged heat shield clamps as re-
quired.
6. Store the exhaust pipes in a safe place until they are rein-
stalled.
EXHAUST SYSTEM
(883R MODELS)
Removal
Refer to Figure 113.
1. Secure the motorcycle on a suitable stand.
2. Remove the heat shields.
3. Remove the nuts and washers securing the front and rear
exhaust pipes to the cylinder heads (Figure 101, typical).
4. Remove the bolts securing the muffler to the support
bracket.
CAUTION
A bowed exhaust flange (
Figure 105
) may
wedge against the exhaust studs preventing
removal. If a flange is tight, remove one of the
cylinder head studs; refer to
Service Methods
in Chapter One. Replace or flatten a distorted
flange.
5. Slide the exhaust pipe flanges (Figure 106) away from
the cylinder head studs.
6. Remove the exhaust as an assembly.
7. Remove and discard the exhaust port gaskets (Figure
108).
8. Loosen the muffler clamp bolts and remove the muffler
from the exhaust pipes.
9. Inspect the exhaust system as described in this section.
Installation
1. Before installing the new exhaust port gaskets, remove
all carbon residue from the pipe fitting surfaces in the ex-
haust port. Wipe the port with a rag, then align the new gas-
ket with the port and push it into place. The new gasket
should fit snugly in the port (Figure 109). Repeat for the
other exhaust port and gasket.
2. If an exhaust stud was removed, install the stud now. Re-
fer to the
Service Methods
in Chapter One.
3. Before installing the exhaust pipes, check that the snap
rings (Figure 110) holding the flanges on the exhaust pipes
fit tightly in the pipe grooves.
4. Position the exhaust pipe assembly, without the muffler,
so the front and rear exhaust pipes fit into the front and rear
cylinder head exhaust pipes. Slide the flanges onto the
mounting studs and install a washer and nut onto each stud
(Figure 101). Install the nuts finger-tight only.
5. Install a new muffler clamp and fastener onto the end of
the exhaust pipes.
6. Slide the muffler onto the exhaust pipe.
7. Turn the muffler so that mounting holes in the muffler
align with the bolt holes in the support bracket. Install, but
do not tighten, the mounting bolts.
8. Tighten the fasteners in the following order:
a. Tighten the cylinder head flange nuts (Figure 101) to
72-96 in.-lb. (8-11 N•m).
b. Tighten the Torca clamp bolt on the muffler to 35-40
ft.-lb. (48-54 N•m).
c. Tighten the muffler mounting bolts to 120-180 in.-lb.
(14-20 N•m).
9. Wipe the exhaust pipes and mufflers with a clean rag to
remove all traces of oil and grease.
10. Install the heat shields and secure with the mounting
clamps.
11. Start the engine and check for leaks. Some smoke will
be evident after starting, especially if rust penetrant was
used on the hose clamps or if oil and grease residue was not
wiped off the exhaust pipes and mufflers.
Inspection
Follow the steps described in
Exhaust System (All Mod-
els Except 883R Models)
in this chapter.
EVAPORATIVE EMISSION CONTROL SYSTEM
(CALIFORNIA MODELS)
All of the California models covered by this manual are
equipped with an evaporative emission control system.
This system is used to prevent gasoline vapors from escap-
ing into the atmosphere. When the engine is not running,
fuel vapor from the fuel tank is routed through the vapor
valve and stored in a carbon canister. When the engine is
running, these vapors are drawn through a purge hose and
into the carburetor where they are burned in the combustion
chambers. The vapor valve also prevents gasoline vapors
from escaping from the carbon canister if the motorcycle
should fall onto its side.
Two evaporative emission control systems are used on
the California models covered by this manual.
378
CHAPTER ELEVEN