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Installing a New Exhaust System

Discussion in 'How-To' started by slowrower, Nov 17, 2007.

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  1. slowrower

    slowrower 2007 Mastiff

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    Ok, lets get started by removing the factory exhaust system. You will need a 3/8" Ratchet with a 1/2" socket and 6" or longer extension to remove the flange nuts and lock washers. Start by removing the four nuts and lock washers that secure the pipes to the engine and them carefully free the chrome flanges. Next using your 1/2" socket, loosen and remove the two bolts that hold the exhaust onto the exhaust bracket (from the underside).

    [​IMG]

    Before (pipe on)

    [​IMG]

    Pipes Off (good time to clean those hard to reach places)

    Next: Remove the Flanges that are secured onto the factory pipe with a metal clip. I used a small screwdriver with a towel over the pipe to keep it from flying off.

    [​IMG]
    [​IMG]
    Next remove the factory exhaust bracket, clean the surface and apply some anti seize onto the bolts.

    [​IMG]

    Here are the original factory flanges, clips and new gaskets (yup there is one extra set there just in case)

    [​IMG]

    The new 2-1 V&H Pipes did not come with plugs for the Oxygen sensors, so a trip to the local parts store from 2 18mm x 1.5mm x 11mm drain plugs. I used a high-temp thread locker to insure a good seal into the pipes.

    [​IMG]

    After installing the flanges and clips (I use waterpump pliers for reinstalling the clips). Tape them to the end so they don't rattle around while your installing the head shields. Ok, time to install the heat shields. First clean the pipes with alcohol to insure no spots appear on your pipes when time comes to fire up the motor. Place the heat shield on the pipe and then thread the clamp through its mount (don't put the clamps on and they try installing the heat shield on the pipes as you can scratch them and its much much harder doing it this way).

    [​IMG]

    Next Step - Remove the old gaskets with a small screw driver and clean up the exhaust port so there is no loose debris .

    [​IMG]

    Here is the old one removed and the new one about to be installed.

    [​IMG]

    Be sure to have some antisieze and apply to the flange bolts and nuts (easier to put the stuff on the nuts).

    [​IMG]

    Tape your bike where tools or the pipes may come in contact. Install the pipes and keep them loose until everything is lined up including the rear exhaust bracket.

    [​IMG]

    Once everything is lined up, tighten it all up and wipe down the pipes, flanges and any place where your grimy hands came into contact.

    For the 2-1 V&H pipes, the rear cover goes on last. All finished, now wasn't that easy?

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Sounds coming soon ..
    Tools needed, 3/8" Ratchet, 1/2" Socket, Small Screwdriver, Water-pump pliers, Anti-Seize lubricant and thread locker. Next comes the K&R Air Filter!
     
    #1 slowrower, Nov 17, 2007
    Last edited: Nov 19, 2007
    Oscar Maldonado and Reaper like this.
  2. FatDog

    FatDog Well-Known Member

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    Cool,

    How do you like the V&H two into one???
     
  3. ohio dog

    ohio dog Active Member

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    Pretty cool pipes
     
  4. Chopper Dave

    Chopper Dave SIICK!!!

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    cool pics slow......yeah...how do you like the sound?
     
  5. Raywood

    Raywood The Pirate
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    Good job Slowrower, GS has some competition now!
    Did you have a pic of the clamp? Where did it clamp to? Did it line up properly?
    You think we can get a full shot of the bike so we can see how good that pipe looks on it?

    Thanks,
    Ray
     
    #5 Raywood, Nov 17, 2007
    Last edited: Nov 17, 2007
  6. Reaper

    Reaper Well-Known Member

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    Nice work Slowrower! Man that is an awesome looking bike.:2thumbs:
     
  7. pisssed

    pisssed pisssed

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    Nice looking pipe! Lets see the barrel end...
     
  8. Oscar Maldonado

    Calendar Participant

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    Repped!
    :cheers:
     
  9. slowrower

    slowrower 2007 Mastiff

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    They sound great, low tone - not too loud, I am recording the sound tomorrow.
     
  10. slowrower

    slowrower 2007 Mastiff

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    Hey Raywood, I 'll add some more photos tomorrow. It was very easy to install and fit the dog perfect. V&H provides the new bracket with th pipes. I love the sound very deep tone - sounds like a bear!!
     
  11. slowrower

    slowrower 2007 Mastiff

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    Thanks Reaper ...
     
  12. Reaper

    Reaper Well-Known Member

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    You are welcome slowrower that is an awesome bike for sure. Also had to give you a rep for the thread.:2thumbs:
     
  13. kickstart

    kickstart Well-Known Member
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    Great How to
    Great looking Scoot
    Great looking pipes

    I'm not breaking your stones but there is a torque sequence to compress the gaskets, I hope you got lucky and have no leaks unless you did it and forgot to mention it.

    :up:

    Torque Bottom flange nuts on both cylinders 20 in/lb. Torque Top flange nuts 60-80 in/lb. Torque Bottom nuts 60-80 in/lb. Loosen bracket bolts that were finger tight and Torque bracket last.
     
  14. hoat

    hoat Well-Known Member

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    good job on the how to hope you don't scrape going right!!!
     
  15. f-okie

    f-okie AllGaveSome-SomeGaveAll

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    Great how to, and a great looking bike.:2thumbs:

    f-okie
     
  16. Gas Man

    Gas Man Cool isn't cheap
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    Nice write up.

    Nice pics.
     
  17. mudslinger

    mudslinger Banned

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    love it. Im going to get those soon.
    you have to post the full on shots.
    Jeff
     
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  18. slowrower

    slowrower 2007 Mastiff

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    Thanks for my first REP!!! add a few more photos.
     
  19. slowrower

    slowrower 2007 Mastiff

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    You will love them mudslinger .. I added more photos and will record some sounds this week. They sound great and are not loud when riding. Also, they will not scrape - they sit higher than the factory pipes. Next photos will be re-jetting the carb and a new S&S air filter. Thanks to all!
     
  20. slowrower

    slowrower 2007 Mastiff

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    #20 slowrower, Nov 19, 2007
    Last edited by a moderator: Nov 19, 2007
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