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exhaust header replacement - 2012 sporty

  • Sida
    Sida
    12 years ago

    Hi All,

    Ive got a 2012 48 and im needing to swap the exhaust header from the standard chrome one to the new black ones i have. Just wondering roughly how long i should allow to get this done. I ride to work everyday so im wondering if i can comfortably get this job done in one evening? 

    The parts dont have any instructions but im not a complete failure with my hands. im thinking it should be about a 2 hour job taking my time. Also are there any 'gotchas' to watch out for when changing this over?

    Thanks

    Pic of what im taking about

  • AJ56
    AJ56
    12 years ago
    Have you got a manual to see what the sequence is? The flange nuts have a specific torque in inlbs not ftlbs. The easiest way is to work your way from front to back of the bike in stages. Put everything on loose, then tighten up the nuts in 3 stages. You shouldn't need to replace your flange gaskets. However it may pay to get a couple in case you damage them when removing the exhaust.

    Overall an easy job and yep probably a couple of hours if you have the right tools.
  • Sida
    Sida
    12 years ago

    I dont have the service manual :/

    is there any specific tools i need?

  • Rooster
    Rooster
    12 years ago

    A couple of hours to do this job is about right, if you have never done it before.

     
    You don't need special tools but a torque wrench is cheap insurance to make sure header nuts are done up "tight enough/not too tight". 120 inch pounds I think is the correct torque setting.
     
     
    Some tips for this job:
     
    - Definitely get new flange gaskets, they are a crush type gasket and are a one time use only. Also they are only a couple of dollars (cheap insurance).
     
    - You may need new interconnect gaskets, this is for the balance (crossover) pipe which also serves as support bracket for the pipes. I have never replaced stock exhaust with stock exhaust so not sure if you can reuse these gaskets. I think they are a cork based gasket and may be reusable.
     
    - Use quarter inch drive ratchet (torque wrench), extension bar and socket. There is stuff all room around the exhaust ports to fit anything let alone a socket, especially on the rear cylinder. Find the thinnest wall socket you can get (1/2 inch size I think) or buy a cheap socket and cut/grind it down. From memory the length of the socket is important too, as a shorter socket enables you to clear cooling fins on the head which are then easily missed with 1/4 inch drive extension bar.
     
    - I disconnect the O2 sensors from the ECU not the pipes and pull the pipes with the O2 sensor still attached, its then easier to get the right spanner on the O2 sensor without damaging it or anything else on the bike. But each will have there own method on this, whatever works for you. I think your O2 sensors are different to 09 sporties so this might be different.
     
    - I wrap socket and extension bar with paper masking tape so that I don't damage or scratch anything on the pipes or the bike, but I am the sort of bloke that gets more paint on himself than the walls as sometimes care goes out the window. But if your careful you may not need to do this.
     
    - Fit your pipes and leave all nuts loose, once your happy with the position, tighten up your flange nuts for each pipe evenly so you get an even crush on the exhaust gasket. Set them to the right torque value (search this site as I have asked this question before) then tighten the rest back to the muffler.
     
    - Most importantly, check the exhaust nuts again within a week after fitting to ensure they are still tight enough. A leaking exhaust will suck in fresh air as well as let gases escape and it may fool the O2 sensors into reading the bike is running to lean which may richen up the AFR unecessarily.
     
     
    Get yourself a manual. You can buy them on ebay for a digital copy for around $10. Then you just print off the pages for the task that you are going to perform that day and when the pages get wrecked with oil and grease from dirty hands you can bin them and your original is still intact.
     
    Good Luck.
     
     
    * Edited incorrect torque setting.
  • AJ56
    AJ56
    12 years ago
    120 inch Lbs... is the correct torque setting.
  • Rooster
    Rooster
    12 years ago
    Thanks AJ, knew there was a 20 in there somewhere.

    * Have Edited earlier post.
  • Sida
    Sida
    12 years ago

    thanks for all the info guys. I actually called HD to see how much they would charge for the install and becuase it was thier fault and they ordered the wrong part i get free installation. I figure free install will save me alot of greif so ive booked it in for Saturday morning. So again thanks for the detailed info, ill keep that on hand if the need arises to change the exhaust.

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