Removing the Exhaust and Draining the Fluids

My goal is to make a little progress every day I can. Today, the goal was to remove the exhaust and drain the fluids. When I mentioned the "chore" removing the exhaust was to my friend Steve (who also has an X1), he referred to it as a "wrestling match." A pretty darn good description.

Because I need to drop the muffler to get at the crankcase plug, the first half of this project was familiar and pretty easy. Remove a couple of bracket bolts on the south end of the muffler and loosen another on the north end.

drop the muffler.jpg

Once that was done, the wrestling match started. The entire time I was struggling to get the exhaust off, I was thinking, "This is going to be a real job when it's time to put it back on."

removing the exhaust.jpg

The first three fasteners were reasonably easy to get at, but there wasn't much space to get a ratchet or a wrench on the last one—the inside stud on the rear jug.

remove the battery.jpg

There's probably an easier way to do this, but I found that if I removed the battery, I could at least get a wrench on it to loosen that last bolt. The challenge seemed to come after all the fasteners were undone, but eventually I got the pipes off the bike and set aside so I could finish up tonight's project and get the fluids drained.

drain the fluids.jpg

Having done this a time or two before, this was the easy part of the day's project. Unfortunately, I discovered some bad news.


When I pulled the plug on the crankcase, I found some shavings on the plug magnet. I'm going to need to track the culprit down. I'm pretty sure it's the OEM clutch plates. There seems to be a rivet that fails. If that's the case, I have a new set of Barnett clutch plates I was planning on installing anyway. At this point though, I'm just making stuff up. I'm going to need to do some investigating before we're done and I put this all back together. Hopefully it will be something pretty obvious. But I'm going to have to take the left side of the bike apart after all—something I was hoping to avoid.

This is all undiscovered country for me at this point, so I'm taking a slow-and-steady wins the race approach. In addition to bagging and labeling all the fasteners and small parts, I'm taking photos of everything so I can keep track in my mind where everything was a month or so from now when I'm putting this all back together—and they make pretty good illustrations for my attempt to describe what I'm doing. Hopefully, writing all this down will help me remember what I was thinking while this was going on and will help with re-assembly.