Exhaust System

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Removal

Remove the lower fairings. See the Lower Fairings topic for more information.

The header is held to the engine with one flange and two bolts per cylinder.

Loosen the eight header bolts with a 6 mm Allen. Remove the bolts and free the header from the engine.

The mufflers are mounted to the passenger footpeg bracket.

Hold the muffler mounting nuts with a 12 mm wrench and loosen the mounting bolts with a 12 mm socket.

Remove the muffler mounting bolts and remove the exhaust system from the motorcycle.

Remove the exhaust gaskets from the cylinder head.

Two separate the exhaust system right and left halves loosen the clamp bolt with a 10 mm socket.

Installation

Fit the exhaust pipes together and tighten the clamp securely with a 10 mm socket.

Install new exhaust pipe gaskets into the exhaust ports. A small dab of grease will help hold it in place, just be aware that it will smoke and burn off when the engine is started.

Fit the exhaust system into place. Insert the muffler mounting bolts.

Line up the flange holes with the bolt holes in the cylinder head. Install the header bolts and tighten them to specification with a 6 mm Allen.

(Header Flange Bolt Torque: 23 N-m or 16.5 lb-ft)

Hold the muffler mounting nuts with a 12 mm wrench and torque the mounting bolts securely with a 12 mm socket.

Install the lower fairings. See the Lower Fairings topic for more information.

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