Kawasaki ZRX1100/ 1200 Competition Meg Series Exhaust INSTALLATION INSTRUCTIONS

0

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

download
STOCK EXHAUST SYSTEM REMOVAL IMPORTANT: This product will greatly improve the flow of your exhaust system. RE-JETTING WILLBEREQUIRED after installation. Please consult your local dealer or a certified techhnicial for appropriate recommendations. You will also need to replace the stock headpipe to cylinder gaskets. These are available at your Kawasaki dealer. 1 Using a 1/4 drive 12mm socket with a 12″ extension and swivel, remove the nuts and split flanges holding the headpipe to the ports. (Retain the nuts and split flanges for installation.) 2 Remove the acorn nut holding the stock muffler in place. (Retain for installation.) 3 Remove the two allen head bolts holding the foot peg bracket and remove the bracket. (Retain for installation.) 4 Remove mid-mount bolt holding the headpipe at the rear of the engine and remove system 3 Install collector assembly onto head pipes. Align all (4) headpipes with the appropriate port on the collector (see figure #1). Using a rubber mallet, tap each pipe into the collector. DO NOT hammer the headpipes all the way into the collector, always make sure that the outlet end of the collector assembly is positioned away from the swing arm and engine sump. 4 Slip the muffler over the outlet of the collector assembly. Align the mount bracket so it is pointing upward (the muffler bracket will be on the inside of the foot peg bracket). 5 Slide the stock muffler mount bolt through the mount hole in the muffler and re-install the stock foot peg bracket using the stock hardware. 6 Re-install the stock acorn nut to the muffler mount bolt and tighten. 7 Align all system components and finish seating the primary headpipes into the collector assembly. 8 Tighten each head pipe at the exhaust port. 9 Install (4) springs, supplied in the hardware kit, from the collector to each headpipe and (2) springs from the muffler to the collector assembly. *IMPORTANT: AFTER A SHORT RIDE CHECK AND RETIGHTEN ALL FASTENERS.

Kawasaki KFX 400 SR4 4 Stroke racing system INSTALLATION MANUAL

0

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

download
Installation Motoworks exhaust 1. Install Motoworks tailpipe with muffler using bolt supplied in kit. (Fig 3) 2. Tighten tailpipe mounting bolt. 3. RECHECK ALL YOUR WORK 4. We recommend that you clean the entire exhaust system with a mild detergent, i. e. glass cleaner prior to starting as any oily residue may cause permanent staining. 5. Before operating check for proper clearance between Motoworks exhaust and ATV i. e. frame, plastic, brake line, fuel line etc. if problems exist, recheck work. Note: It is normal for the new exhaust to emit white smoke the first time you start the ATV. This is from the oil used during manufacturing.

Kawasaki 2000- ZX-12R Ninja exhaust system Installation Instructions

0

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

download
1. Remove the lower fairing. Remove the lower radiator mounting bolts, loosen the upper bolts and pivot the radiator forward to provide access to the exhaust nuts (flange nuts). Remove the oil cooler mounting bolts and pivot the oil cooler forward to provide access. 2. Remove the existing exhaust system and save the flange nuts for reuse. Save the stock exhaust can mounting bolt and nut for reuse as well. 3. Inspect the exhaust gaskets. Replace if necessary. 4. Assemble the head pipes 1, 2, 3, and 4 by matching the joints of the same color to the pair of front Y-pipes. Do not install the exhaust springs at this time. 5. Place a billet aluminum Mouthpiece ring Z on each TiForce head pipe. (see figure 3 for details) . 6. Attach the assembled head pipe sections to the exhaust ports, but do not tighten the flange nuts fully, allowing for some adjustment in the remaining steps. Reuse the flange nuts saved from step 2 above. Make sure the ends of the head pipes fit flush and snug in the ports and Mouthpiece ring Z before tightening. 7. Install the S-Bend to the front section of the head pipes and two Y-pipes. 8. Go back and retighten the head pipe flange nuts per factory specifications – make sure the head pipes and Mouthpiece ring Z are centered in each port. 9. Slide the TiForce end can into place. 10. Loosely attach the two rubber bands, stainless steel bands K, and stay / hanger G to the end can using the supplied 6mm hardware H. (See figure 1) . 11. Place the bands approximately 118 mm from the edge of the end can. (See figure 2) . 12. Using the stock provided mounting point on the passenger foot peg, and using the stock-mounting bolt, mount the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G. 13. Attach the supplied springs to all the joints, starting from the head pipes and working back to the end can. 14. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance

Kawasaki ZRX-1100 / 1200 exhaust system Installation Instructions

0

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

download
1. Remove the existing exhaust system and save the flange nuts for reuse. Save the stock exhaust can mounting bolt and nut for reuse as well. 2. Inspect the exhaust gaskets. Replace if necessary. 3. Attach the head pipes 1, 2, 3 , and 4 to the exhaust ports of their respective cylinders, using the flange nuts saved from step 1 above. Loosely apply the flange nuts for now, allowing for ome adjustment. 4. Attach the Y-pipe collectors to the head pipes. Please note that one collector goes to pipes #1 and #4 and one collector goes to pipes #2 and #3 (collectors are labeled). Make sure the ends of the head pipes fit flush and snug in the ports. Do not install the springs at this time. 5. Install the S-Bend to the rear of the two Y-pipe collectors. Do not install the springs at this time. 6. Go back and retighten the head pipe flange nuts per factory specifications – make sure the head pipes are centered in each port. 7. Slide the TiForce end can into place on the S-bend pipe. 8. Loosely attach the two rubber bands, stainless steel bands K, and the stay / hanger G, to the end can using the supplied 6mm hardware H. (See figure 1) . Make sure that the rubber bands fully cover the stainless bands to prevent scratches to the can. 9. Place the bands approximately 108mm from the edge of the end can. (See figure 2) . 10. Go back and tighten the exhaust flange nuts per factory specification. Do not over tighten. 11. Using the stock provided mounting point on the right passenger footpeg, and using the stock mounting bolt, mount the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G. 12. Attach the supplied springs to all the joints, starting from the head pipes and working back to the end can. 13. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance. 14. Carefully align the two stainless bands K so that they are parallel to each other, and spaced properly on the can (refer to step 11 / figure 2), then tighten the 6mm hardware H and the stock mounting bolt hardware. Make sure that the rubber pads fully cover the band(s). USE CAUTION WHEN TIGHTENING THE 6MM HARDWARE AND THE TWO BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN. 15. Using some brake and contact cleaner on a clean rag, carefully wipe down the entire exhaust system to remove any residual oils, anti seize, fingerprints and dirt prior to starting the motor. FAILURE TO CLEAN THE TUBING AND CAN MAY RESULT IN PERMANENT STAINING OF THE SYSTEM WHEN HEATED. 16. Check that all hardware is properly tightened, and then start the motor and check for exhaust leaks

Harley-Davidson V-Rod Destroyer Indy Series Exhaust REMOVAL AND INSTALLATION

0

Filed Under (Harley Davidson) by admin on 24-10-2010

download
STOCK EXHAUST SYSTEM REMOVAL (DESTROYER) 1. Remove both collector bolts. 2. Remove nuts from both front and rear exhaust cylinder head flanges using a 13mm socket. 3. If the Racepak is installed, remove both O2 and EGT sensors from the front and rear head pipes. 4. Carefully remove complete exhaust from the motorcycle. STOCK EXHAUST SYSTEM REMOVAL (V-ROD) 5. Loosen clamp bolt at front of the collector using a 13mm socket. 6. Remove muffler bracket bolt using a 13mm wrench. 7. Carefully remove muffler and collector assembly from motorcycle. 8. Remove nuts from both front and rear exhaust cylinder head flanges using a 13mm socket. 9. Carefully remove head pipes from motorcycle. 10. Remove the stock exhaust flanges and circlips from both the front and rear head pipes. If the circlips are bent or twisted they should be replaced, Harley-Davidson part number #65045-01 We also recommend replacing the stock exhaust gaskets, Harley-Davidson part number #65109-01 INDY SERIES EXHAUST SYSTEM INSTALLATION 1. Identify front head pipe #7-8002. Install the stock flange and circlip. Install the exhaust gasket and front header pipe, leaving the flange nuts hand tight. 2. Repeat the above step for the rear head pipe #7-8006. 3. Slip the megaphone/collector assembly onto the head pipes, secure with the four springs supplied using the spring puller tool. 4. Rotate the exhaust so there is adequate clearance in all places. 5. Tighten the cylinder head flange nuts for both the front and rear head pipes. 6. Tighten both the EGT and O2 plugs on the front and rear head pipes. 7. Clean all fingerprints from the exhaust using a contact cleaner (or other non flammable cleaner). Fingerprints will leave stains on the pipe once the motorcycle is started. 8. You are now ready to start the motorcycle.