What is the easiest way to remove my muffler? It seems the rear cylinder's header is not removable from the can. I just couldn't reach the nuts. Short of removing all sorts of plastic I tried to weld, grind, and paint on the muffler while on the quad. Now in order to make it look like it was done at the factory I need to do it right.
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In order to facilitate the removal of the rear exhaust flange, you will have to remove the plastic. I approached it from the driver's side. HTH

Steve

 

Just the black plastic or the entire side?

 

If it's similar to the 650 which I think it is....just jack up the backend and take off the right rear tire ( facing it from the front) and then you can reach in there with a long extension and a universal swivel and spin the nuts right off......be careful don't lose the gasket........I changed mine pretty easy that way without taking any plastic off except the seat for light.........Dave

 

Thanks

 

You should not have to remove the plastic. It may make taking off the exhaust easier, but you have to deal with taking off the plastic, and putting it back on. Try using a wrench coming from the top (under the seat) or either a universal swivel thingy (pretty sure that is technically right) and a loooong extension coming from near the muffler itself. Hope this helps.

 

I removed all the back plastic, to make it a whole lot easier to get to the exhaust bolts on the rear cylinder, and remove the rear shock.

It only takes about 10 minutes to remove the rear plastic, and it makes the whole job so much easier.

It's really only 6 fasteners for the rear rack, and 6 for the entire back plastic.. Oh yea - you have to remove the gas cap too.

Reminder: Don't forget to unplug the rear tail light.