[superrman77]

Guys I have a bad exhaust on my 88 foreman. I am wanting to remove it. I removed the mounting bolts and the bolts where it goes into the header pipe. Is there something else I should be doing to make it come off easier?

 

[86_4trax4x4]

If i remember right there were 4 or 5 bols that held the muffler on. I know one is about your knee behind a plate you have to remove.

 

[SamUK]

It may be corroded into the head, quite a common issue in the U.K. IIRC there are the bolts into the head, one connecting the header to the muffler and possibly one holding the header to the frame. If you have them all undone and it still won’t budge start the motor up and let it get hot, get some good welding gloves on and wiggle/twist it. If that doesn’t work then you have two options, proceed with caution and apply penetrating oil over a few days or use brute force and ignorance!
If you take your time it will come of quite easily, frustration makes these kind of jobs worse at times. You’ll find a copy of the factory service manual under the sub-section ‘manuals and schematics’ in this forum, that should help identify the amount of bolts holding it on and the correct removal procedure.

 

[Duck0fDeath]

How far have you gotten? You have to remove the muffler and heat shield around it before you can remove the header pipe. The muffler heat shield has a couple bolts on the bottom that are somewhat concealed. After your sure all the bolts are removed from the muffler, smack and twist that sucker off.

 

[superrman77]

I am not taking the header pipe off. I just want to replace the muffler with a cobra exhaust I picked up.
Thanks

 

[shadetree]

more than likely the old muffler at the gasket is rusted over, it will take some doing with some wd-40 or whatever you use ?, squirt in in around the gasket and flange, do some prying, work the muffler off the header pipe. sometimes they can be a pain to get off if they have never been removed in the past ?. but the muffler will come off !. just takes some twisting and pulling, a few curse words here and there, big hammer, lots of blood, sweat , and tears !..lol.

 

[superrman77]

Well thanks for the help. I got it off. I didn't realize there was a hidden bolt behind the frame cover. I put the cobra on and ended up cracking it where the bolt hole is in the front. I may see if I can get it welded. Anyone have a line on a good stock exhaust?

 

[shadetree]

Well thanks for the help. I got it off. I didn't realize there was a hidden bolt behind the frame cover. I put the cobra on and ended up cracking it where the bolt hole is in the front. I may see if I can get it welded. Anyone have a line on a good stock exhaust?

ebay will be your best bet, or a salvage yard . be warned !..even used mufflers for your model on ebay will not be cheap !. why ?, cuz they know they are discontinued, and if you want it bad enough ?, then they can charge high dollar.