What the trick on removing the muffler on the P650? I want to drill it and need to remove it to cut/weld the end cap. It looks like there is a slip fitting and clamp for the front cylinder pipe that is just upstream of the muffler, but the rear cylinder pipe doesn't appear to have the same fitting. Do you have to disconnect the pipe at the rear cylinder and then loosen the front cylinder clamp (at the muffler) to get the muffler off?

By the way, Goop is a wonderful thing and as much plastic as I am breaking, I may have to buy stock in the company.

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rty,

The rear pipe does have to come off from the cylinder and I had a hard job getting the joint apart for the front pipe. I took the clamp off then used a large screwdriver to pry the joint at the seams (not between the pipe halves, but at the slots on the rear half of the pipe(you'll see what I mean)). This loosened the joint enough to pull it apart without reaming on it too hard.

 

The bolts on the head are tricky take the tire off and use a long extension to reach straight back from the rear, at the slip joint I used a rubber hammer and tapped on the exhaust till it slid out. Putting it back on and getting the manifold bolts on will make you cuss..

 

I had the ecact same thing happen last night. I borrowed a long drill bit from my neighbor and thought I would be an easy 30 min job.


Then I started Looking at it.

Has anyone took off the rear plastic and possibly the rear tire and done the mod on the bike?


I think I would rather fool with that than taking off that exhaust system, of course I am not much of a mechanic.

 

You can remove the rear plastic in under 30 minutes. Not difficult, just a butt load of bolts/screws to remove. I remove all the racks and plastic from mine each spring to perform a "Spring" cleaning, painting & through GI-Service. The removal of the rear headpipe is a pain in the a$$. Even with all the extensions, wigglers, gigglers and a thin wall socket it is a challenge to install and ensure the gasket stays in place. You can remove all the screws from the left side of the rear plastic and it will permit you to "swing-up" that side to permit some add'l access. Patience is the key element here.