Header install advice

I searched but didn't really find anything so here goes.

I've been wanting to buy a set of Motad headers for my 2002 but had a hard time justifying the price.  Came across a slightly used set of Delkevic headers.  Price was right so I bought em.  Unfortunately, it doesn't have a centerstand stop so that will have to come off.

1. The swap looks pretty straight forward but was looking for any tips.
2. Also, anyone with a PC3 map for catless headers, staintune cans, and K&N filter.  I've been using Cozye's map but realize it will likely need to be modified.

Appreciate your comments.

[image: View Post]Hawkeye Driver, on 28 September 2010 - 09:38 PM, said:

I searched but didn't really find anything so here goes.

I've been wanting to buy a set of Motad headers for my 2002 but had a hard time justifying the price.  Came across a slightly used set of Delkevic headers.  Price was right so I bought em.  Unfortunately, it doesn't have a centerstand stop so that will have to come off.

1. The swap looks pretty straight forward but was looking for any tips.
2. Also, anyone with a PC3 map for catless headers, staintune cans, and K&N filter.  I've been using Cozye's map but realize it will likely need to be modified.

Appreciate your comments.

i put on a set of motads about a year ago and it was a bitch. the first set didnt line up right, the center stand hit the headers. the second set was a little better. but i still had to trim the center stand down a little. i dont remember too much else other than that. take your time, try and get a second set of hands to help you line everything up. i take it you got a new set of gaskets right? your gonna need them. becareful not to damage the gaskets at all.

as far as the pc map is concerned, do the right this and have a custom map done. no two bikes are the same  and no map other than your own custom map will be perfect for your bike...

Have a jack handy to help push the rear section of the header onto the rear downtubes. There's a map here for download (click the 'Files" tab up on the main header); was posted by Tinyminds. Should give you a great head start.

I used the rubber stop removed from the cat when i installed my catless headers and JB welded it to the centerstand to give me enough clearance from the chain. file or dremel the rubber to conform to the centerstand. I even drilled small safety wire holes so I could safety wire it also. A little black paint and it doesn't stand out.

Thanks for the advice.  Headers are sure easier with in I4.  I'll pick up gaskets this weekend and if I get time do the swap on Sunday.  Hadn't thought about using a jack.  I was just going to remvove the center stand as I don't need it on a daily basis.  For maintenance chores I was planning on just bolting it on minus the spring.  Only takes about 2 minutes, at least that was the case on my old XS650.  Thanks for pointing me to the map as that was concern most on my mind.

Somewhere on here somebody mentioned using grease to hold the gaskets in place.  That's a great suggestion that I wish I had read before I did mine.  Those gaskets are supremely soft too, it doesn't take much to mangle them.  Might also want to soak your current bolts/clamps with WD-40 or oil to loosen them a bit before you pull them off.  

[image: View Post]dutchinterceptor, on 30 September 2010 - 12:38 AM, said:

Somewhere on here somebody mentioned using grease to hold the gaskets in place.  That's a great suggestion that I wish I had read before I did mine.  Those gaskets are supremely soft too, it doesn't take much to mangle them.  Might also want to soak your current bolts/clamps with WD-40 or oil to loosen them a bit before you pull them off.

Two excellent tips, especially the one about WD40/oil!! I use PB Blaster for these kinds of fasteners, it creeps better than the WD. 1-2 drops is usually all it takes! Along the same lines, you might want to have some new studs on hand, just in case.