Exhaust Header Swap

[Canadian FJR]

How much work in invloved in replacing the header? Does the rad need to be removed completely or is there enough room?

I searched but no find.

Canadian FJR

 

[SkooterG]

Changed your topic title to be a bit more accurate...........

It's around here somewhere. I am pretty sure most have reported that you just unbolt the radiator at the bottom and rotate it out of the way, keeping it out of the way by tying it off to something.

 

[Mihalis fjr]

Hi Canadian!

A lot of work..!I have replace my header after a bad bend from a wayside.First you must take out the silencers,side cowlings,gas tank(lift from the front for unpluging the conector of the sensor)not completely out,plug of the sensor,coolant,radiator completely(no enough room),and..header.Beware the two upper bolts of the radiator when you will screw it special the left bolt,is a little difficult to screw it in because there are a lot of wires.(i destroye a little the threads on the frame...When you refill the coolant you must pick a little the plastic to unscrew the closure and with a funnel and a hose then you can refill the coolant..

 

[Canadian FJR]

Thanks for the reply, sounds like a winter job while things are apart to do the valves.

Canadian FJR

 

[vtwinn]

Mine was done buy the PO and is starting to get

Ragged so I will need to redo them soon as well.

 

[SkooterG]

Mine was done buy the PO and is starting to get

Ragged so I will need to redo them soon as well.

?????

I have no idea what you are talking about?????

 

[04Graphite]

If I had to guess, I'd say he's talking about header wrap.

But to address the OP, I have pulled mine without tearing the whole bike apart, all it takes is a little bit of mechanical skill and some finesse, and remember not to force it.

Remove the lower fairings, fender, mufflers; loosen the O2 sensor, lower header bolts, and the lower radiator support. That should give you just enough room to get it out. Now, remove the nuts at the top, it's tight, there's not much room, but a good Master Driver set and decent ratchets and extensions(the kind with a wobble notch work great) will do the trick. Once you get all 8 of them off then support the header, and remove the lower header support bolts. And there you have it...it's out.

Notice I did not disconnect the O2 sensor...remove the wire from it's clips and if you're really nice and gentle it'll turn enough times to come outta the pipe. I hate those plastic wire connectors and have horrible luck with breaking them.

I've tried to be as thorough as possible but inevitably there is some piece that I left out or forgot, so your results may vary.

Hope this helps.

 

[Mihalis fjr]

It is not so difficult and gruesome to pull the radiator, just wants some attention when you put it back you must look a bit screwing the upper bolts..