Topic: exhaust removal and reinstall

[evinrude7]

i'll be pulling the 4 into 4 exhaust off the bike soon to replace crush gaskets, clean and do any minor repairs on the pipes.  how long should it take to remove and reinstall?  any tips/things to watch out for?  first time doing this.

[PeWe]

First time removing and mounting the 4-4 takes tripple time.
Do not tighten the clamps too much, threads will collapse and/or clamp crack.
Mounting them.
I start with pipe 2 that must be swinged on the other side of side stand.
The pipe must be completely on the exhaust spigot, if not the rear bolt holding passenger foot peg and both pipes will not fit thru pipes and frame.
Do not hammer the pipe onto the spigot.  You do 1-2 then 3-4 or opposite.
Pipe must be lowered by removing rear bolt. Then press pipe max on the exhaust spigot and swing rear upwards to fit rear bolt.
I used a strap around cyl block holding the pipes deep on the spigot while fitting the rear bolt first times holding the 2 pipes.
No problem to mount all 4 pipes in 30 minutes. First time might take 1 hour. But with my hints here easy!

I do it with bike on center stand without any problems.
The screws holding the spigots can be a problem, loosen up by vibrations if not properly tightened. Stock X-bolts are 22mm countersunk screws. I have ordered M8 x 25mm countersunk allen heads for easier retighten if coming loose.

[evinrude7]

First time removing and mounting the 4-4 takes tripple time.
Do not tighten the clamps too much, threads will collapse and/or clamp crack.
Mounting them.
I start with pipe 2 that must be swinged on the other side of side stand.
The pipe must be completely on the exhaust spigot, if not the rear bolt holding passenger foot peg and both pipes will not fit thru pipes and frame.
Do not hammer the pipe onto the spigot.  You do 1-2 then 3-4 or opposite.
Pipe must be lowered by removing rear bolt. Then press pipe max on the exhaust spigot and swing rear upwards to fit rear bolt.
I used a strap around cyl block holding the pipes deep on the spigot while fitting the rear bolt first times holding the 2 pipes.
No problem to mount all 4 pipes in 30 minutes. First time might take 1 hour. But with my hints here easy!

I do it with bike on center stand without any problems.
The screws holding the spigots can be a problem, loosen up by vibrations if not properly tightened. Stock X-bolts are 22mm countersunk screws. I have ordered M8 x 25mm countersunk allen heads for easier retighten if coming loose.

thank you pewe. 

[Gordon]

Don't make the same mistake many previous owners make and assume there are no gaskets in the exhaust ports and put another set on top of them. 

They get very flat and very black from soot, and it's easy to think there's nothing there to remove, but there is. 

[Johnie]

A mechanics pick does a nice job on getting those crush washers out.

[przjohn]

Don't make the same mistake many previous owners make and assume there are no gaskets in the exhaust ports and put another set on top of them. 

They get very flat and very black from soot, and it's easy to think there's nothing there to remove, but there is.

A good set of seal picks are nice tools to have for this type of job. I have had a 3 piece set for over 30 years and they are a great addition to any tool chest.

[evinrude7]

don't leave the old gaskets in there.  check.

[flybox1]

Save a Head...Install Studs.

[ekpent]

 If your taking the exhaust spigots off the head to replace the crush washers my suggestion is to have a good reliable hand held impact driver that works well with a very good fitting bit and maybe a spare bit also. I have broke bits trying to get the screws out before. Sometimes they are easy and some can be a real pain    Heat and pentrating oil can help also.

[Kevin D]

It's a good time to clean all the road grunge and chain lube off.