twinx1649
11-04-2014, 10:39 AM
We all know there aren't many options for new exhaust systems and I wanted to share my recent experience in case some of you are trying to decide what to do. First off, the new system (head pipes and mufflers) needed to all be replaced because the old stuff wasn't saveable. If your parts are decent, only replace what you need as the eBay stuff is not-so-great. Here's what you need to know:
Step 1, Both new head pipes are symmetric, the originals aren't so you will need some lengths of 3/4 pipe to bend the angles close enough to work.
Step 2, Install header flanges (cast finned coupler) on pipes which may require flattening the head pipe in a soft-jaw vise to make it round enough to install. It's important to install them FIRST because once you start bending the pipe it will be too oval to install later.
Step 3, Make sure the pipe flange fits inside the head exhaust port; mine were too large and needed to O.D. ground down on a bench grinder to fit properly.
Step 4, Loosely install mufflers and grind the mounting holes open in whatever direction necessary to fit the bike (mine were WAY off).
Step 5, Try to mate head pipe to muffler keeping in mind you will need to make many bend attempts to get it right. I pre-bent mine first using the original pipes as a template and still made many tweaks before I was satisfied.
Step 6, Add spacers to the muffler mounting stud and bolt necessary to get the mufflers angled properly to give you the necessary clearances and make sure the tips are equal looking from the rear of the bike. I found it necessary to apply a little foot pressure on the rear of on of the mufflers once everything was bolted down tight so it all looked right. I'm not and advocate of using the "foot" but it worked so I'm passing it along, LOL.
Note: Leave the protective plastic cap on the end of the 3/4 pipe as it provides a snug fit to the I.D. of the pipe and will help avoid damaging the pipe in case you want to return it to Home Depot when you're done ; )
Now that it's done I'm happy with the results and it sounds a bit louder than stock which is fine.
Cheers,
Jim
Step 1, Both new head pipes are symmetric, the originals aren't so you will need some lengths of 3/4 pipe to bend the angles close enough to work.
Step 2, Install header flanges (cast finned coupler) on pipes which may require flattening the head pipe in a soft-jaw vise to make it round enough to install. It's important to install them FIRST because once you start bending the pipe it will be too oval to install later.
Step 3, Make sure the pipe flange fits inside the head exhaust port; mine were too large and needed to O.D. ground down on a bench grinder to fit properly.
Step 4, Loosely install mufflers and grind the mounting holes open in whatever direction necessary to fit the bike (mine were WAY off).
Step 5, Try to mate head pipe to muffler keeping in mind you will need to make many bend attempts to get it right. I pre-bent mine first using the original pipes as a template and still made many tweaks before I was satisfied.
Step 6, Add spacers to the muffler mounting stud and bolt necessary to get the mufflers angled properly to give you the necessary clearances and make sure the tips are equal looking from the rear of the bike. I found it necessary to apply a little foot pressure on the rear of on of the mufflers once everything was bolted down tight so it all looked right. I'm not and advocate of using the "foot" but it worked so I'm passing it along, LOL.
Note: Leave the protective plastic cap on the end of the 3/4 pipe as it provides a snug fit to the I.D. of the pipe and will help avoid damaging the pipe in case you want to return it to Home Depot when you're done ; )
Now that it's done I'm happy with the results and it sounds a bit louder than stock which is fine.
Cheers,
Jim