Remove the driver's side floorboard (makes life easier and is easy to do). Go ahead and remove the heat shields on the two header pipes, but you can leave the one on that covers where the two pipes come together (just loosen it a bit) at the Cat and fit it loosely on the new pipe(after you've removed the old pipe, of course) before you put it on. Loosen the clamp that holds the crossover pipe to the bottom of the frame, and the muffler type clamp that holds the crossover to the header pipe (no need to remove the heat shield for the crossover pipe). Remove the bolt that holds the header to the frame (located just under the Cat). If you have a 1/2" swivel socket it makes removing the exhaust nuts that hold the header to the head a bit easier, at least on one of the nuts (front), but if not, it can still be done. It helps if you have an extra set of hands to hold the header when you remove all the nuts, but you can make do by yourself. Pull the old header off and out of the crossover pipe, and put it on an old sheet or bath towel to keep from scratching the heat shield. Get a flashlight and a small bladed screwdriver and carefully remove the old exhaust gaskets from both heads. You can usually do this by gently prying the gasket away from the side of the port, then grabbing it with a pair of needle nose pliers...if it's really stuck in there, you might have to do a bit more to get it all out...just try not to gouge the ports with the screwdriver. Install new gaskets in the heads. Remove the heat shield from the old header that covers the CAT...fit it loosely on the new header before installation. Remove the old flanges and split rings from the old header and install on the new one. Install the new header into the heads, being careful not to bugger up the new gaskets...it helps to have another set of hands here, but it can be done alone. Install loosely all 4 nuts onto the studs holding the header to the exhaust ports, then loosely install the bolt that holds the X to the frame, enough to hold everything in place. Tighten each nut on the exhaust studs EVENLY until you have them snugged down well enough not to leak. I'm sure there's a TQ setting for these nuts, but I don't know how the hell you'd get a TQ wrench on them, so I just go by "feel". Just do them evenly, and don't overtighten (don't want to break off a stud...you can tell when they are tight). Tighten the hanger bolt below the X. Fit the crossover pipe to the new header and kind of snug the clamps up, but not to the point where you can't move things a bit, so you can line everything back up when installing the left side Muffler back on the bike. Install both mufflers, after loosely fitting the heat shields back on them. I like to use some high temp silicone (red) sealer on the inside of where the muffler slips onto the new header...makes it easier if you have to remove them later, IMO. Make sure the mufflers are slipped on the header far enough and that the clamp is positioned so that you can tighten it easily. Bolt the muffler to the hanger to support everything. On the left side, slip the muffler onto the crossover pipe, making sure everything is lined up properly and bolt to the hanger. Make sure the crossover is positioned correctly both in the muffler, and to the header pipe on the other side, then tighten down the crossover hanger bracket, the muffler clamp for the left side, and the clamp where the crossover connects to the new header. Tighten the muffler clamp on the right side. Install the heat shields back onto the new header pipe, making sure you can get to all the clamps to tighten them down. Position the heat shields for the mufflers and tighten those clamps. Position the X heat shield properly and ensure that the....
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Topic: Lead Pipe CUSE 6 2011 (Read 1052 times)