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Fitting a Full Exhaust (to a 98 ZX6R) |
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The tools you’ll need are:
Phillips head screwdriver
Allen key
Sockets. 14,12 and 10mm
Torque wrench
The standard system. [ex1]
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Ex 1
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Remove both lower fairings [ex2]
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Ex 2
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Undo the three nuts on the end can and the hanger nut [ex3]
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Ex 3
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Hold the can from behind and pull out the hanger bolt. Then slide the end can off backwards. [ex4]
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Ex 4
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The standard can is heavy [ex5] and restrictive [ex6]
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Ex 5
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Ex 6
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Remove the lower radiator bracket and swing the radiator forward [ex7]
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Ex 7
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Undo the header bolts and pop the pipes [ex8]
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Ex 8
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Support the headers and remove the mid pipe bolt [ex9]
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Ex 9
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One exhaustless bike [ex10]
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Ex 10
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New headers ready for fitting with new gaskets for a good seal [ex11]
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Ex 11
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The larger pipes necessitated removing the upper radiator bolts and lowering it carefully down behind the front wheel to get all the nuts on the headers done up. A small amount of push and pull was required to line the pipes up. Once they are all in, fit the mid pipe retaining nut and tighten it to 18 ft/lbs of torque. Then do up the header bolts evenly to 16.5 ft/lbs of torque. The copper gaskets will squash so go back over the header nuts from the first one you did up to the last again. [ex12]
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Ex 12
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Slide the tail pipe and the can onto the headers and fit the retaining springs. Then fit the bracket around the can and bolt it to the hanger. Double check everything. Once you are satisfied, clean down the system with alcohol to remove any grease and skin oil so it doesn’t burn onto the pipes. Fire the engine and quickly feel around the exhaust ports for any leaks. By the time you get to number four the pipe is already quite hot. Shut the bike down as soon as you are done. [ex13]
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Ex 13
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If everything is OK then give the pipes another quick once over with alcohol where you touched them and refit the radiator [ex14]
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Ex 14
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Refit the fairings and its time to go for a ride. [ex15]
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Ex 15
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The oval can makes the bike look more balanced, [ex16] and is much less restrictive. [ex17]
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Ex 16
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Ex 17
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Thanks to Aussie Ninja for this article!
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