YAMAHA V-STAR 650 EXHAUST SYSTEM REMOVAL AND INSTALLATION

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Filed Under (Yamaha) by admin on 18-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the right hand frame cover to avoid scratching it. 2. Remove the nuts that mount the rear header to the cylinder head. 3. Loosen the pinch clamp on the inlet end of the lower muffler. 4. Remove the two bolts that mount the mufflers to the muffler bracket, located between the two mufflers. Save the hardware for reuse. 5. Pull the rear head pipe out of the exhaust port. Slide the muffler assembly with the rear head pipe attached, rearward, disconnecting it from the front head pipe. Set the assembly aside. Note: Keep the front head pipe attached to the motorcycle, it will integrated with the new exhaust system. 6. Remove the muffler mounting bracket from the frame and set it aside. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Install the V&H muffler mounting bracket (stamped 272) to the frame using the stock hardware and mounting location. Refer to figure 1 2. Slip the T-bolt band clamp (supplied) over the straight pipe that is welded to the front muffler. 3. Slip the front muffler assembly over the stock head pipe. Slide one dog bone shaped nut plate (supplied) under the bracket that is welded to the backside of the muffler. Attach the muffler to the mounting bracket using two of the 5/16″ flange head bolts (supplied), but leave them loose at this time. Refer to figure 1. 4. Install the rear header assembly to the exhaust port using the stock 8mm nuts, but leave them loose at this time. 5. Slide one dog bone shaped nut plate (supplied) under the bracket that is welded to the backside of the rear muffler. Attach the muffler to the mounting bracket using two of the 5/16″ flange head bolts (supplied), but leave them loose at this time. Refer to figure 1. 6. Unscrew all of the hose clamps (supplied) until they are completely loose. Mark the top edge of both heat shields with the location of the mounting clips that are welded to the backside. Position the front heat shield over the head pipe and feed the tail end of the hose clamps into the clips. Be sure that each hose clamp is engaged with both clips. Repeat this step with the rear heat shield. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. Leave them loose at this time. 7. Align the mufflers so they are parallel when viewing from the right side of the bike, and tighten the 5/16″ flange bolts on the back side of both mufflers. 8. Tighten the two header flange nuts on the rear head pipe. 9. Tighten the T-bolt clamp at the slip joint of the front muffler. 10. Rotate the hose clamps on both heat shields so they are accessible with a screw driver and tighten each of them evenly. Note: The edge of the heat shield should just cover the weld on the inlet of each muffler, if not, adjust the heat shield for correct alignment

1995 – 1999 HONDA CBR 900RR AKRAPOVIC BOLT-ON STREET LEGAL EXHAUST SYSTEM Installation instructions

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Filed Under (Honda) by admin on 12-12-2010

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REMOVAL OF STOCK EXHAUST SYSTEM 1. put the motorcycle on a side stand, we recommend a racing stand 2. unscrew and remove bolts from the muffler at the muffler – link pipe (header assembly) connection (Figure 1) 3. unscrew and remove the bolt from the metal hanging bracket and remove the muffler (Figure 2 & 3) INSTALLATION OF THE AKRAPOVIC BOLT-ON EXHAUST SYSTEM installing the muffler: 1. remove the stock gasket and install the copper gasket from the Akrapovic kit in the groove in the CNC ALU flange (Figure 4) 2. correctly orient the muffler and place it near the link pipe/header assembly 3. when the muffler and the link pipe are together, attach using the titanium bolts from the Akrapovic kit. Coat each bolt individually with bolt sealant before installing. (Figure 5) Tighten the bolts only hand tight – do not fully tighten! (Figure 6) 4. correctly position the carbon-fiber clamp and slide it onto the muffler – bear in mind the left offset of the carbon-fiber clamp viewed from the rear (Figure 7). WARNING: open the clamp to slightly wider than the diameter of the outer sleeve of the muffler – do not scrape it along the muffler outer sleeve! (Figure 8) 5. tighten the carbon-fiber clamp onto the stock bracket on the frame – use the stock bolts or the replacements from the Akrapovic kit, if supplied (Figure 9) 6. make sure that the BOLT-ON system is not touching any other parts of the motorcycle ! 7. example of the correct position of the installed Akrapovic BOLT-ON system (Figure 10) final installation: 1. Tighten the titanium bolts on the CNC ALU flange at the muffler – link pipe connection and also tighten the bolts on all of the brackets and clamps to which the exhaust system and the other dismounted parts of the motorcycle are attached 2. clean grease spots: a. muffler – titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 or equivalent) b. muffler – carbon-fiber outer sleeve: use a soft dry cloth Cleaning will prevent spots from burning onto the surface. Do not use aggressive chemical cleaners, because they can damage the sticker. 3. Check the operation of the brakes and suspension. Make sure all the bolts are sufficiently tightened. In case the exhaust system touches the cowling or other parts repeat the adjustment of the exhaust system or contact your authorized dealer.

YAMAHA V-STAR 1300 exhaust system INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Install the bracket (Stamped 439-P, supplied) to the motorcycle chassis using the 10 x 20mm hex head bolt (supplied) and two of the stock mount bolts in the bottom holes (Figure 3). 2. Remove exhaust system and heat shields from protective packaging and place them on a non-abrasive surface such as a blanket or carpet. Using a non-permanent marker or tape, mark outside edge of each heat shield to show location of mounting clips that the hose clamps will loop through (Figure 4). 3. Apply a small amount of anti-seize compound to the threads of the stock O2 sensor and install it into the header assembly. NOTE: Be careful not to overtighten or get anti-seize compound on the sensor tip as this could damage or affect the sensor function. 4. Carefully lay header assembly into the heat shields and loosely install the hose clamps #20 on head pipe heat shields and #24 on collector heat shield (supplied) by feeding the tail end of the clamp into the heat shield clips. Take note of screw head direction (Figure 5), for adjustment purposes they must be accessible when system is installed. NOTE: Do not tighten the clamps at this time. 5. Using stock dome nuts, carefully install system into exhaust ports. (Assistance may be required). NOTE: Install but do not tighten the exhaust nuts at this time. 6. Remove the muffl er heat shield and baffl e assembly from their protective packaging. Place them on a non-abrasive surface such as a blanket or carpet. 7. Insert the large hose clamp (#56, supplied) into the clip on the muffl er heat shield. 8. Carefully slide the baffl e assembly (without damaging the fi berglass packing) into the muffl er heat shield and align the holes in the heatshield with those in the baffl e. Secure the baffl e with the 1/4-20 x 1/2″ button head screws (supplied) and tighten the hose clamp. 9. Install the 5/16″ x 1 1/4″ hex head bolt, washers and locknut (supplied) in the muffl er clamp (supplied) and slip the clamp over the end of the baffl e tube. 10. Slide nut plate (supplied) inside the bracket welded to backside of baffl e (Figure 6). 11. Install the muffl er assembly onto the collector, making sure it slides forward enough to align the edge of the bracket welded to the baffl e with the edge of the mounting bracket. 12. Attach the muffl er assembly to the mounting bracket using the 5/16″ x 5/8″ fl ange head bolts (supplied). 13. Tighten exhaust port nuts evenly on both cylinders. 14. Tighten the muffl er clamp and the 5/16″ fl ange head bolts, securing the muffl er assembly. 15. Insert the O2 sensor plug back into harness and tuck harness back into its original position. Reinstall the cover. 16. Check alignment of heat shields making sure the ends meet squarely to the collector heat shield. Tighten the hose clamps on all the heat shields when properly aligned. 17. Reinstall right side passenger and rider fl oorboards and tighten the 12mm bolts. 18. Check for adequate clearance between all exhaust system components and motorcycle accessories prone to heat damage. 19. All hardware must be properly tightened and the exhaust pipes thoroughly clean before starting motorcycle

1998 – 2002 KAWASAKI ZX 6R AKRAPOVIC BOLT-ON STREET LEGAL EXHAUST SYSTEM Installation instructions

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Filed Under (Kawasaki) by admin on 05-11-2010

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1. install the copper gasket from the Akrapovic kit in the groove in the CNC ALU flange (Figure 4) 2. correctly orient the muffler and place it near the link pipe/header assembly (Figure 5) 3. when the muffler and the link pipe are together, attach using the titanium bolts from the Akrapovic kit. Coat each bolt individually with bolt sealant before installing. (Figure 6) Tighten the bolts only hand tight – do not fully tighten! (Figure 7) 4. correctly position the carbon-fiber clamp and slide it onto the muffler – bear in mind the left offset of the carbon-fiber clamp viewed from the rear (Figure 8). WARNING: open the clamp to slightly wider than the diameter of the outer sleeve of the muffler – do not scrape it along the muffler outer sleeve! (Figure 9) 5. tighten the carbon-fiber clamp onto the stock bracket on the frame – use the stock bolts or the replacements from the Akrapovic kit, if supplied (Figure 10) 6. make sure that the BOLT-ON system is not touching any other parts of the motorcycle ! 7. example of the correct position of the installed Akrapovic BOLT-ON system (Figure 11) final installation: 1. Tighten the titanium bolts on the CNC ALU flange at the muffler – link pipe connection and also tighten the bolts on all of the brackets and clamps to which the exhaust system and the other dismounted parts of the motorcycle are attached 2. clean grease spots: a. muffler – titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 or equivalent) b. muffler – carbon-fiber outer sleeve: use a soft dry cloth Cleaning will prevent spots from burning onto the surface. Do not use aggressive chemical cleaners, because they can damage the sticker. 3. Check the operation of the brakes and suspension. Make sure all the bolts are sufficiently tightened. In case the exhaust system touches the cowling or other parts repeat the adjustment of the exhaust system or contact your authorized dealer.

Kawasaki ZX-14 Indy Series Exhaust System REMOVAL AND INSTALLATION

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Filed Under (Kawasaki) by admin on 25-10-2010

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Remove and place the lower fairings in a safe place, to separtate them unhook the rivet at the bottom. The right side lower fairing will need to be trimmed for proper exhaust clearance. Remove the fairing knee panels. Two rubber grommets retain the panel after bolt removal, light force is required to pull panel off. Remove the tank cover. Four rubber grommets and two plastic hooks retain the panel after bolt removal, pull outward to remove from grommets then pull forward and up, light force is required. Remove mid fairing sides. Undo pushpin located on the fairing backside. Note: Blinker connectors must be disconnected before pulling the fairing too far. Remove the left and right muffl ers. Remove the stock header. Note: Be careful not to damage the radiator while removing the stock header and installing the new header leaving the fl ange nuts loose at this time. Install both collectors 7-40020 and 7-40022 holding them to the headers install the four springs 7-30002 from the header to collector spring tabs. Install collector 7-40014 by installing two springs 7-30002 from collector to collector spring tabs. Note: A small amount of WD-40 at the pipe joints will help to fi t them together. Install the megaphone on the header assembly using one of the original muffl er mounting bolts and nuts removed in step 6, mount the megaphone to the forward muffl er mount located at the footpeg. Tighten the header nuts and then remove the megaphone. At this point the right side lower fairing needs to be trimmed. A template is supplied (Page 4) to outline the clearance cut that is needed on the right side lower fairing, we recommend using a dremel tool or a die grinder. The template should give you the necessary clearance but some fi tments may vary. After making the cut lightly sand the edges being careful not to scratch the paint. Clean all fi ngerprints from the exhaust using contact cleaner (or other non fl ammable cleaner). Fingerprints will leave stains on the pipe once the motorcycle is started. Try a test fi t. If you feel more clearance is needed, mark the fairing and remove it, trim until there is at least a 1/4″ of clearance. Reinstall the megaphone and check that the O2 plug is tight. You are now ready to start your motorcycle. Check for exhaust leaks and oil leaks. Shut off the bike and re check the oil level

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