phukit
Novice Class
Posts: 40
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posted March 23, 2004 06:50 PM
Changing exhaust tips?
I'm getting a full Muzzy exhaust for my 12, I don't have a manual but I was just wondering if there's anything to look out for? Any tips to make it easier? Or is it as simple as it looks, just pull the left/right fairings and loosen the radiator to get to it all? When putting it all together I imagine it would be best to torque down the header 1st then loosely bolt the rest of the system together and tighten it all down from the front to the rear to help prevent leakage? Does it come with high temp sealant for the headers? Sorry so many questions, I always do my own maintenance (except valve adjustments) but this is my 1st exhaust and I'm really looking forward to it, I'm always hearing this system for this bike gains about 15-20HP. Your experiences?
Torque specs for the bolts would be greatly appriciated too. Thanx for any info you can give.
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2002ZX12R
  
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TurboBlew
Moderator
BUSY DOING THE SCHIAVO
Posts: 4590
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posted March 23, 2004 06:57 PM
First time? Take the radiator off. Also remove the KLEEN system and silicone or pay Muzzy $36 for the blockoffs. (or make your own)
Just make sure that the one piece header goes on straight. You may need a partner to help set it in place. Ive seen quite a few Muzzys put on crooked. :O
Make sure you replace the copper exhaust gaskets. You'll need 4.
Also if you have a 2000-01 model, replace the single fan with an aluminum blade one from Muzzys. $35
Also mixup your coolant at 30% coolant/65% distilled water and the rest Watter Wetter. You'll have to heat cycle the bike once you get it back together to get all the air out of the cooling system.
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Official Charter Member of the RIDERS OF KAWASAKI MEMBERSHIP REVOCATION CLUB
Also a BadAss Internet Forum Moderator 4 Hire!! Come at me brah!
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zrexpilot
Expert Class
Posts: 470
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posted March 23, 2004 07:19 PM
I just put some lowering dog bones on my '04. Had to pull the exhaust off to get the bottom link bolt out. (bummer) Anyway i took both fairing side off so you can get to the header from both sides. Didnt do anything to the radiator you can get to the nuts with extensions and a swivel at the end. Dont think you need new gaskets either, put a dab of grease on them to hold them in place. Put your new system on and bolt it up. I did my stock exhaust by myself with it complete with end can and all, but it would probably be easier to do the head pipe first then your can.
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vozizm
Needs a job
Got Nothing Witty To Say
Posts: 4417
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posted March 23, 2004 08:02 PM
i would also put new gaskets... no need to cut corners on your baby!!!
when i installed dogbones... i cut that bolt off and installed a new one in the opposite direction!!
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zrexpilot
Expert Class
Posts: 470
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posted March 23, 2004 08:35 PM
quote:
i would also put new gaskets... no need to cut corners on your baby!!!
when i installed dogbones... i cut that bolt off and installed a new one in the opposite direction!!
You know what the real bummer is ? I put that bolt back in the same (wrong) direction. (in my best Homer voice) Doh !
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ZXLNT
Needs a job
Kawpuke Extraordinare
Posts: 2853
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posted March 24, 2004 05:04 AM
Also space out the radiator on the side that has the bracket. I use a T-collar like what fits inside the rubber donuts to keep them from collapsing. Then just use a longer bolt. It spaces radiator away from the headpipes just a little more yet still fits the bodywork fine...
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phukit
Novice Class
Posts: 40
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posted March 24, 2004 10:16 AM
Thanx guys.
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2002ZX12R
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mitch
Parking Attendant
Posts: 6
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posted March 25, 2004 04:39 PM
quote:
quote:
i would also put new gaskets... no need to cut corners on your baby!!!
when i installed dogbones... i cut that bolt off and installed a new one in the opposite direction!!
You know what the real bummer is ? I put that bolt back in the same (wrong) direction. (in my best Homer voice) Doh !
Mario,
I dropped the shock and was able to get the bolt out.
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zrexpilot
Expert Class
Posts: 470
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posted March 25, 2004 10:05 PM
Mario,
I dropped the shock and was able to get the bolt out.
Doh ! Why didnt I think a that.
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Gambit-ZX12R
Parking Attendant
Posts: 2
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posted March 29, 2004 07:26 PM
If I never sold my '03 I would not be buying a new exhaust for my 04!
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Don't stop unless you sure they can catch you.
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