VT1100-SABRE.org

Prepare

You'll need to get:

• New crush gaskets (BikeBandit Part#: 76728-001). Make sure you get the old ones out before putting in the new ones - it might take a small screwdriver to pry them out.
• A crowfoot wrench set will help too - especially when torquing the front pipe.

Removal

If the muffler will be separated, loosen the muffler joint bolts and muffler band bolts.

1. Remove the four exhaust pipe joint nuts.
2. Remove the two mounting bots, nuts and exhaust pipe/muffler as an assembly.
3. Remove the old crush gaskets - a small screwdriver may be needed to remove them.

Installation

Note: If the exhaust system was not disassembled, steps 1, 2 and 6 are not necessary.
      The Exhaust pipe band bolts (3 & 4) are under the heat shields.

Refer to the illustration above:

1. Before mounting the exhaust system, assemble the front and rear mufflers by tightening the muffler joint bolts (2) and the muffler bolts (1).
2. Temporarily tighten the exhaust pipe band bolts (3 & 4).
3. Make sure that the new crush gaskets are installed correctly.
4. Insert the exhaust flange onto the cylinder head studs with the flange "UP" mark facing up and loosely install the exhaust pipe joint nuts (5 & 6).
5. Hold the exhaust pipe/muffler assembly and loosely install the two mounting bolts and nuts (7).
   After mounting the exhaust system tighten each fastener in the sequence below.

6. Tighten the muffler band bolt (1) and muffler joint bolts (2) to the specified torque:

   Band bolt: 14 ft-lbs
   Joint bolt: 20 ft-lbs

7. Tighten the exhaust pipe band bolts (3 & 4) to the specified torque.

   Exhaust pipe band bolt: 14 ft-lbs

8. Tighten each pair of exhaust pipe joint nuts (5 & 6) alternately in 2 - 3 steps

   Exhaust pipe joint nut: 17 ft-lbs

9. Tighten the mounting bolts (7) to the specified torque

   Mounting bolts: 17 ft-lbs

Note: Re-torque exhaust pipe joint nuts (5 & 6) after a couple short rides.