Hey guys, quick update on this project.
I installed the TI Remus Headers today, and from start to finish it took 60 minutes. It was one of those very satisfying projects that went exactly according to plan, with no busted knuckles and no surprises.
I have to give a shout out to fellow board member David M. who sold me the headers. His packaging job for shipment was second to none, and the headers are in as new condition, just like he said. What I love about cool online forums like this is that these bikes and parts have a great life... David was finished with the headers and now I get to enjoy them. There's something very elegant about all of that.
Overview of the install process:
- First I loosened all the bolts to make sure none of them were seized. The one nut for the O2 sensor on the right side was a little hard to loosen, but nothing crazy. I literally use this very long adjustable wrench, just to get more leverage on it. Everything else was easy.
- Once I knew I could get everything taken apart, I then took off all the nuts and bolts. You have to remove the two bolts holding the bracket and C clamp apparatus that holds the OEM exhaust on near the catalytic converter. This bracket gets entirely removed, and the bolts returned to their original location after removing the bracket. You don't need the bracket with the Remus exhaust because one, it's super light, and two, the way it connects to the front and rear of the bike makes the bracket not necessary. I could have saved myself 10 minutes by removing both bolts once the OEM Exhaust was off the bike, but I wanted to make sure the Remus headers fit properly first, in case I had to reinstall the OEM header which would require the bracket. This made it more difficult to remove and then replace the final bolt holding the bracket assembly onto the bike (there are two bolts) because I had to work around the newly installed header.
- After removing all the bolts, and also the two exhaust springs (a Vice Grip works perfectly for this) I carefully removed the OEM header. Nothing tricky, just slides right off.
- Next, after admiring the lightness and absolute beautiful build quality of the Remus TI headers, I installed the Y pipe to the OEM exhaust, sliding it on and letting it just rest there while I installed the headers.
- Next, I examined the original OEM header to determine which header goes on which side. Not tricky, but measure twice, cut once.
- Then starting from the front, I attached each header, hand tight, making sure the header was fully seated properly on each head.
- Then, I carefully adjusted everything to fit properly, making some subtle adjustments. The pieces fit together snugly, so I don't think there will be any leaks of any sort.
- After lining everything up, I carefully tightened down the bolts where the headers connect to the bike.
- Lastly, I attached the O2 sensors, and installed the 2 original OEM springs in the original locations, and then the two additional springs that Remus provides to connect the header to the Y pipe.
- Finally, I tightened everything down, and started the bike. Everything seems to run great. I will take it out for a shakedown run before leaving on my trip.
Thanks for the advice and tips everyone. This was a fun little project.
Pictures below.
Mullet
Bend, Oregon
