also as mentioned above, lots of people reuse exhaust port gaskets without issue. If there is an issue though, what a pain in the azz to remove the exhaust again just to replace those. Just replace them and be done with it is my .02.
the head pipe comes with everything you need to install it including new exhaust port gaskets.
As pointed out above, the o2 sensor placement is crucial - black is back just remember that.
As for installation:
1.the night before you are going to install, get the exhaust port gaskets out of the box and put them in the freezer. Trust me on this.
2.Pull off driver's floorboard (if stock 9/16" wrench on back of front bolt and 5/16" allen head)
3.take off all heat shields (5/16" socket)
4.take off both saddlebags and right side cover
5. disconnect both grey and black o2 sensor plugs behind right side cover and feed wire back down
6.Unbolt the muffler clamps on both sides (if stock 5/8" socket)
7.unbolt the muffler hanger bolts (2 on each side at the rear of the muffler 1/2")
8.slide and wiggle your mufflers off (if they're tuff I find a rubber mallet and towels wrapped around the chrome and few strikes takes care of that)
9.unbolt the crossover hanger bolt in front of your rear tire at the bottom (1/2"). No need to remove the 3/16" allen head screws from the bracket.
10.unbolt the (2) 1/2" bolts at rear and front exhaust ports (I find a 1/2" swivel socket 3/8" drive works best)
11.unbolt the transmission bracket bolt (9/16" facing down)
12.pull exhaust off
13.remove o2 sensors from the stock head pipe and immediately go put them in the new head pipe in their proper locations (black is back meaning rear exhaust pipe). **IMPORTANT** DO NOT TOUCH SENSOR TIPS AND DO NOT GET OIL ON THEM AND USE ANTI-SEIZE on the threads (don't get it on the tips)
14.pull out old exhaust port gaskets I find it easiest when reinstalling them(if you don't have the proper insertion tool from Jims) to clean the exhaust port surfaces with steel wool or fine grit sandpaper and lube with a light coat of oil. Then grab your new ones out of the freezer and they should slide right in place.
15. remove retaining rings (easy to do with a pair of regular pliers) and the chrome flanges at head pipe where they mount to cylinders from each pipe. These parts will be transferred to your new head pipe. Pay attention to orientation of chrome exhaust flange
16.follow the FM instructions to remount your head pipe. There is a specific sequence to install and tighten down all bolts in the manual. Follow it.
17.use anti seize on the 1/2" nuts at the exhaust ports on the head. You'll thank yourself later for this one.
18.reinstall mufflers, clamps, heat shields.
19.enjoy your new cooler running bike.
good luck...
^^^^^^
I don't do wrenching really and have some Fuel Moto pipes on the way from USA but what a fantastic precise and helpful post this is above.
I just put mine on, follow the instructions they send and no problem. I stuck a piece of cardboard in between the pipe and cam cover before tightening everything to make sure there was clearance.
^^^^^^
I don't do wrenching really and have some Fuel Moto pipes on the way from USA but what a fantastic precise and helpful post this is above.
Well done sir
thanks.. another thing to make mention of if your pipes have dual bungs on them. Make sure when you put the plugs in the bungs you're not using to use anti-seize on the threads. If for example you use the 12mm sensors/bungs and the pipe comes with 18mm bungs as well. Later on you may decide to use something like a Powervision with auto-tune which utilizes it's own 18mm sensors then you will play hell getting those 18mm bung plugs out. Can't stress enough, anti-seize is your friend on exhaust installs.
I have printed both Ultranutz and Fuelmoto instructions. I should be able to do this.
I have heard mention of snap rings but neither of those print outs mentions them.
What am I missing there ?
BTW, placed the order for pipe and mufflers last night, got a UPS tracking number this morning. They'll be here Tuesday, that's pretty good and the Monster Ovals I ordered were $170 cheaper than the dealer wanted.
oops. I corrected the above (step 15).the snap rings being referred to are on your stock head pipe and are located behind the flanges that mount to the exhaust ports. Once you unbolt the (2) 1/2" nuts at each cylinder exhaust port the chrome flange will slide down the pipe along with the snap rings. Just grab a pair of pliers and work one end of the snap ring over the lip on the headpipe and work the ring off. Pay attention to the groove in the flange as the snap rings fits into it when putting things back together.
in the pic below, the flanges are at the top, the retaining rings are at the bottom
10-08-2014 | 08:51 AM
