Re-hanging entire stock exhaust 2004 FJR

[Satori88]

I will be removing the entire exhaust system to have patchwork done "up flow" from the O2 sensor. Any pointers on rehanging th exhaust, ie tightening sequence, etc. All six gaskets will run me about $50.00 so I'm hoping to do it right the first time.

Cheers, ~CG

 

[skyway]

I will be removing the entire exhaust system to have patchwork done "up flow" from the O2 sensor. Any pointers on rehanging th exhaust, ie tightening sequence, etc. All six gaskets will run me about $50.00 so I'm hoping to do it right the first time.Cheers, ~CG

Start at the header and work backwards.

 

[S76]

Just had mine off and back on. Upon inspection, the header gaskets were all evenly compressed and uniform looking so I did not replace them and have not had any problems. The gaskets at the muffler were also easily reused. Not to be cheap, but it just wasn't required.

As stated, hang the entire system, start at the front and tighten your way back.

 

[tyronewildman]

While you have the exaust system off, this would be a good time to remount the center stand bracket assy. To remove & lube all the suspension leavers, swing arms, dog bones, etc. U have to remove the centerstand assy and that's a bitch with the exaust system on. Here's part of a write up I did on the job. (It's not the 2 stand bolts but it is the 4 stand bracket bolts that are the problem).. Later,,, De

The center stands on the pre ‘04s (with their extra added gusset) may break, but they darned sure won’t fall off because of loosened bolts. These 4 bolts & nuts were the tightest & hardest to loosen of any I have ever seen. These 4 bolts were inserted from the outside, so the exhaust system has to be pried over & down to remove the bolts. While the book says to remove the exhaust system, you can do it without removing the headers by removing the muffler bolts & exhaust bolts to the center stand. When remounting the center stand, insert these 4 bolts from the inside so the exhaust won’t interfere. On the front 2 bolts I used a thick flat washer under the bolt head and purchased 2 thinner nuts (blue thread locker too) for proper exhaust clearance. I made sure that the weight of the bike was on the center stand before tightening these 4 center stand bolts/nuts.

 

[Satori88]

While you have the exaust system off, this would be a good time to remount the center stand bracket assy. To remove & lube all the suspension leavers, swing arms, dog bones, etc. U have to remove the centerstand assy and that's a bitch with the exaust system on. Here's part of a write up I did on the job. (It's not the 2 stand bolts but it is the 4 stand bracket bolts that are the problem).. Later,,, De
The center stands on the pre ‘04s (with their extra added gusset) may break, but they darned sure won’t fall off because of loosened bolts. These 4 bolts & nuts were the tightest & hardest to loosen of any I have ever seen. These 4 bolts were inserted from the outside, so the exhaust system has to be pried over & down to remove the bolts. While the book says to remove the exhaust system, you can do it without removing the headers by removing the muffler bolts & exhaust bolts to the center stand. When remounting the center stand, insert these 4 bolts from the inside so the exhaust won’t interfere. On the front 2 bolts I used a thick flat washer under the bolt head and purchased 2 thinner nuts (blue thread locker too) for proper exhaust clearance. I made sure that the weight of the bike was on the center stand before tightening these 4 center stand bolts/nuts.

Good stuff, Thx Wildman, I have close to 20,000 miles on it...time for more PM.

 

[Satori88]

Just had mine off and back on. Upon inspection, the header gaskets were all evenly compressed and uniform looking so I did not replace them and have not had any problems. The gaskets at the muffler were also easily reused. Not to be cheap, but it just wasn't required.
As stated, hang the entire system, start at the front and tighten your way back.

I will be careful while unhanging...the question is Do I feel lucky punk, well do I!? I wont order the gaskets until I check the damage. Should I go full torque on all the header bolts BEFORE placing the mufflers on? I have had problems with the Vision's exhaust in the past.