Header removal help please


Header removal help please

Postby whatscooking » Tue May 26, 2015 11:10 pm

I would like to ask before start in on removing the exhaust system, my first time. What will I find when I start removing the twelve nuts that hold the pipes to the head? Any tricks here would be nice. The bike has very low miles. Does it help to soak things down and with what? Can heat be used? I just don't want to destroy anything.
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Re: Header removal help please

Postby Michael Vidovic » Wed May 27, 2015 3:51 am

Mine came off easily even though I was nervous about breaking something. Be careful when putting it back together not to over tighten
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Re: Header removal help please

Postby EMS » Wed May 27, 2015 8:21 am

Put something soft under the bike, just in case you drop the exhaust after all fasteners are removed. 8)
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Re: Header removal help please

Postby Jeff Bennetts » Wed May 27, 2015 11:14 am

When you put it back on make sure all he old donut gaskets are gone from the head and put a couple dabs of grease or high temp silicone on the backside of the new gaskets to keep them in place.

Don't over tighten the stud nuts, re torque them after a couple of heat cycles.
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Re: Header removal help please

Postby FalldownPhil » Wed May 27, 2015 11:17 am

Cover the rear half of the front fender for a "just in case" .
The first time you remove the pipes, it is possible for you to whack the fender :-)
If you loosen the rear hanger bolts but don't remove them, you can then remove all the collars and collets in the front without the pipes coming down in the front.
Then cradle the front of the pipe with one hand while removing the rear bolt with the other and you should have the removal pretty much in hand :-) (pun intended)
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Re: Header removal help please

Postby Larry Zimmer » Wed May 27, 2015 11:30 am

Further to Jeff's comments: It might take some 'jiggling' to get the pipes flanges back into the head. What ever you do, don't use nut torque to 'pull' the pipes into place. Those studs are little guys. Torque spec is something like 7 - 9 ft-lbs. Use a 1/4" drive torque wrench. You don't want to have to be trying to remove a broken stud. And, as Jeff mentioned, check the nut torques after 2 or 3 rides. Vibration and heat will have things settled good.
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Re: Header removal help please

Postby EMS » Wed May 27, 2015 1:35 pm

Larry Zimmer wrote: . You don't want to have to be trying to remove a broken stud. .



Never seen a broken stud, but plenty of them being pulled out of the head :roll: :roll:
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Re: Header removal help please

Postby Larry Zimmer » Wed May 27, 2015 9:00 pm

Good to know, Mike. Thanks. Wouldn't be much fun helicoiling #3, though. (Or 1,2,4,5,6 either.)
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Re: Header removal help please

Postby whatscooking » Wed May 27, 2015 9:19 pm

Thanks for the tips. The stock system has blown through with a hole where the muffler hooks on. I have a D&G six into one to put on with new copper gaskets.
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Re: Header removal help please

Postby FalldownPhil » Wed May 27, 2015 9:36 pm

Don't tighten anything on the DG until it is all in place. You will need wiggle room :-)
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Re: Header removal help please

Postby whatscooking » Mon Jun 01, 2015 9:09 pm

Got it back together today with a ride. Everything came apart real nice and went together better than I thought it would with all those pipes lining up. The worse part was cleaning all the fingerprints off. Instructions say to use grease or anti sieze when you slide the pipes together, if I do another one ill skip that step.
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Re: Header removal help please

Postby FalldownPhil » Mon Jun 01, 2015 9:20 pm

This deserves an "Atta Boy" :-)
Congratulations. It will be easy from now on.
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