| PART NUMBER | TOOL NAME |
| PFSX916 | SNAP-ON WRENCH |
To facilitate removing exhaust pipe header nuts, use SNAP-ON WRENCH (Part # PFSX916).
Figure 4-69. Exhaust system: XR 1200X: 1. Fastener, rear muffler mount; 2. Fastener, mount to frame; 3. Fastener, front muffler mount; 4. Flat washer; 5. Grommet, front mount (2); 6. Fastener, front muffler mount (2); 7. Front muffler mount; 8. Washer-nut; 9. Sleeve; 10. Fastener, interconnect bracket (3); 11. Interconnect bracket; 12. Nut (4); 13. Retaining ring (2); 14. Exhaust port gasket (2); 15. Exhaust pipe flange (2); 16. Carriage bolt; 17. Flanged nut; 18. Lower clamp; 19. Muffler gasket (2); 20. Lower muffler; 21. Upper muffler; 22. Rear muffler mount; 23. Bolt, muffler-to-muffler (2)
Removal
Mufflers
1. See Figure 4-69. Remove forward muffler mount fastener (3) and washer-nut (8).
2. Remove two bolts (23) fastening mufflers together.
3. Slide upper muffler (21) back off header pipe to remove.
4. Remove rear muffler mount fastener (1).
5. Rotate lower muffler (20) counterclockwise to disengage from the rear mount (22) and slide back off header pipe to remove.
6. Remove mount grommets (5) and sleeve (9).
7. Inspect rear mount (22) and replace if damaged.
8. Inspect muffler seals (19) and replace if necessary:
- a. Pull seal out of muffler using a hook-type tool.
- b. Push new seal into place being careful not to distort or damage the new seal.
Header pipes
1. Remove mufflers.
2. Disconnect O2 sensor connectors. Remove sensor if necessary. See 4.12 OXYGEN (O2) SENSOR.
3. See Figure 4-69. Loosen or remove head pipe heat shields to gain access to header pipe flange nuts (12).
4. Remove flange nuts (12) and pull flanges (15) off from studs.
5. Remove nut (17) and carriage bolt (16) from lower clamp (18).
Note. Be careful not to drop or hit header pipe assembly. Damage to the catalytic converter may result.
6. Remove header pipe assembly from vehicle.
7. Inspect exhaust port gasket (14) and replace ifnecessary.
- a. Pry gasket from exhaust port in cylinder head being careful not to damage the bore.
- b. Push new gasket into place with the larger ID facing the header pipe, as shown in the inset in Figure 4-69.
8. Remove retainer rings (13) and flanges (15) if necessary.
9. If necessary, remove mount brackets (7, 22) and interconnect bracket (11).
Installation
| FASTENER | TORQUE VALUE | |
| Muffler mount to frame, rear fastener: XR 1200X | 15-20 ft·lbs | 20.3-27.1 Nm |
| Muffler mount to frame, front fastener: XR 1200X | 45-50 ft·lbs | 61.0-67.8 Nm |
| Interconnect bracket to frame fastener: XR 1200X | 30-33 ft·lbs | 40.7-44.7 Nm |
| Exhaust flange nut: XR 1200X | 96-120 in·lbs | 10.8-13.6 Nm |
| Exhaust clamp, lower nut: XR 1200X | 30-33 ft·lbs | 40.7-44.7 Nm |
| Muffler to front muffler mount fastener: XR 1200X | 120-180 in·lbs | 13.6-20.3 Nm |
| Muffler to muffler bolt: XR 1200X | 120-180 in·lbs | 13.6-20.3 Nm |
| Muffler to rear muffler mount fastener: XR 1200X | 120-180 in·lbs | 13.6-20.3 Nm |
| Exhaust heat shield clamps | 20-40 in·lbs | 2.3-4.5 Nm |
1. See Figure 4-69. If removed, install flanges (15) and retaining rings (13).
2. If removed, install rear mount (22), front mount (7) and interconnect bracket (11).
- a. Tighten fasteners (2) to 15-20 ft·lbs (20.3-27.1 Nm).
- b. Tighten fasteners (6) to 45-50 ft·lbs (61.0-67.8 Nm).
- c. Tighten fasteners (10) to 30-33 ft·lbs (40.7-44.7 Nm).
Note. Do not damage exhaust port gaskets (14) when positioning header pipes in exhaust port area.
3. Install new exhaust port gaskets (14).
4. Install head pipe assembly in position and loosely secure lower clamp (18) with carriage bolt (16) and flange nut (17).
5. Install flanges (15) and finger-tighten nuts (12). Do not tighten until mufflers are installed.
6. Install mufflers.
7. Place lower muffler (20) on header pipe. Rotate until rear mount fastener (1) can be installed. Loosely install fastener (1).
8. Place upper muffler (21) on header pipe.
9. Install muffler-to-muffler bolts (23) finger-tight.
10. Install grommets (5), sleeve (9), fastener (3), washer (4) and washer nut (8). Tighten finger-tight.
11. Tighten the exhaust flange nuts (12) to 96-120 in·lbs (10.8-13.6 Nm) in the following sequence:
- a. The front exhaust pipe lower exhaust flange nut
- b. The front exhaust pipe upper exhaust flange nut
- c. The rear exhaust pipe lower exhaust flange nut
- d. The rear exhaust pipe upper exhaust flange nut
12. Verify the exhaust header pipes do not contact the drive belt idler pulley. Verify that there is sufficient clearance for proper operation of the rear brake pedal. Tighten nut (17) to 30-33 ft·lbs (40.7-44.7 Nm).
13. Tighten fastener (3) to 120-180 in·lbs (13.6-20.3 Nm).
14. Tighten muffler to muffler bolts (23) to 120-180 in·lbs (13.6-20.3 Nm).
15. Tighten rear mount fastener (1) to 120-180 in·lbs (13.620.3 Nm).
16. Install heat shields. Tighten to 20-40 in·lbs (2.3-4.5 Nm).
17. Install and connect the O2 sensors. See 4.12 OXYGEN (O2) SENSOR.