Exhaust header pipe installation instructions
This instruction is in two parts: first part is on how to remove the existing header pipe system from your bike - the second part is about installing your new Dobermann Performance header pipes.
If you are installing a Dobermann Performance exhaist muffler too, please see these instructions on exhaust muffler installation.
Header Pipe removal.
- First thing to do is to remove the exhaust can – please see the details on exhaust removal here.
- After the exhaust can is removed, you should remove the lambda sensor(s) from the header pipes.
- There is a connector on the lambda sensor cable – disconnect the connectors before unscrewing the lambda sensor(s) from the header pipe.
- There may or may not be a support bracket that holds the rear end of the header pipes to the engine or frame.
- If your bike has a support bracket, loosen the bolt now, but do not take it off yet.
- If there is no support bracket on the rear part of the header pipes, support the header pipes so they will not drop down when you loosen the cylinder head connection. (Blocks of wood are excellent here)
- Header pipes may consist of several different parts that are held together by bolts or springs. You can now remove springs and bolts that hold the header pipe system together.
- Now it is time to disconnect the header pipes from the cylinder head, and this is an area that requires you to TAKE CARE!
- Most header pipe systems have a flange with two holes that fits over two studs in the cylinder head. To remove the header pipes from the cylinder heads, you need to remove the nuts and washers on the two studs so you can slide the flange down the header pipes. IMPORTANT: Especially on forward facing cylinder heads, the nuts and the threaded stud can get extremely dirty, so clean the area thoroughly and soak the nut and thread in WD-40 before undoing the nut. You only want to remove the nut, but if the nut is stuck badly to the threaded stud, you will remove the stud from the aluminum cylinder head. It is not a disaster if it happens, but as aluminum threads are always fragile, it is preferred to keep the stud firmly attached to the cylinder head. If the stud comes out of the cylinder head, use more WD-40 so you can remove the nut, clean the stud completely and put it back in the cylinder head and secure it with some medium duty thread lock.
- Now you should be able to remove the header pipes from the bike – either in one piece or part by part.
- If you need to take the headers apart from the bike in separate parts, spray some WD-40 on the pipe connections (Usually the “Pipe over Pipe” type), to make it easier to take them apart.
- There is a compressible gasket between the cylinder head and the header pipes. It usually stays in the cylinder head, but may also decide to stick to the header pipe when you pull it out.
Header Pipe installation
- Keep the header pipes in the box until you are ready to install it.
- Don’t put the pipes on the floor where you can kick it or drop tools on it. This is really basic, but it happens more often than you would think – so take care !
- It is sometimes possible to reuse the compressible gasket between the cylinder head and the header pipes, but we never recommend doing so.
- The gasket is not a part of our delivery, so get the number of gaskets you need from your local dealer (You need one gasket per cylinder)
- Look at the pipes to make sure you know where the different part goes. There may be a certain installation order you need to follow, but as there are only a few parts involved, it is not rocket science to figure it out.
- The trick is to assemble the different pipes “loosely” on the bike and not tighten anything before you are sure that everything is in place.
- The “Pipe over pipe” connections between the different parts of the header pipe assembly will be much easier to work with a bit of WD-40 spray.
- When you install the pipe(s) that goes to the cylinder head, tighten the two nuts by hand and then one turn backwards to make sure that the cylinder head connection is not tight.
- If there is a support bracket in the rear end of the header pipe system, install it now, but do not tighten the bolt up yet.
- Now you should have all parts loosely installed on the bike and you can start to tighten nuts and bolts.
- The cylinder head nuts at tightened first. IMPORTANT: Refer to the workshop manual for your bike to see the correct torque, and make sure to use a suitable torque wrench.
- Next thing to tighten is the rear support bracket (if present).
- Last is the connection between the different pipe parts in the header system. Attach the springs using the included spring puller, and tighten the clamp bolts. (Some systems have springs, other have clamp bolts)
- Now the header pipes are installed on the bike and all connections are tightened.
- Double check that there are no loose connections by tapping the pipes with your hand.
- Wipe the header pipes clean and remove all traces of the WD-40 spray you may have used during assembly.
- Reinstall the lambda sensor(s) and tighten them to the torque specified in the workshop manual for your bike.
- Don’t forget to assemble the lambda sensor connectors again.
- That’s it – now install the exhaust can – see the instructions here.