Daman
.020 Over
I installed the Jardines a month or so ago and got great help from Gary(G-man). This is his detailed email on installation that i found way more useful than the Jardine manual. Hope he won't mind me posting this here. All credit for this to Gary!
Remove OEM exhaust--------all you---Good Luck.
There are three (3) fundamental elements of the Jardine:
Header Manifold (hdr) that attaches to engine block exhaust ports.
Right Side Pipe/Collector/Muffler/Cross-Over (rsp)
Left Side Pipe/Muffler (lsp)
Before you actually install there are some "dry fit" steps I encourage you accomplish.
1. hdr to block flatness, alignment & registration.
Place hdr exhaust flanges on a flat surface (marble counter top works great) and check for flatness of hdr flanges.
All 3 flanges should be flat against surface simultaneously. Looks for gaps in say one flange and surface when two other flanges are gapless.
If any gaps are present and they are less than approx .060" we can fix by selective torque-ing to block and or the use of multiple gaskets.
Leave OEM exhaust gaskets in-place for now.
Place hdr on block studs and check for center-to-center registration of respective hdr flange to block exhaust port.
Each flange should engage the machined & gasket-ed block exhaust port equally, circumferentially, easily and simultaneously!!
I pray that this step yields good simultaneous registration else we have got our work cut out for us!!!
2. hdr and rsp collector flange circularity.
This is done on shop floor without either part attached to bike.
This interface is a line-to-line fit which can easily go astray!!
This is also the most important fitment for the ultra copper RTV exhaust sealant.
Engage the hrd and rsp collector flange so that full engagement to mechanical stop is achieved.
Now rotate the two elements at least two revolutions both CW and CCW.
Rotation should be relatively free of binding and will also remove any "high-spots" impeding good circularity between elements.
High spots will be identified by metal scoring...repair as necessary...it's real important when final assembly is done!!!
3. practice installation of hdr & rsp...let's you know what you are in for!!
The trick is to familiarize yourself with the gymnastics necessary for effortless (not really) install.
This is important because you will only have about 5 minutes of time after application of ultra copper RTV exhaust sealant to collector flange before it starts to set-up!!!
4. Loosely install heat shields to hdr...trust me!!..it may sound strange but will save you much angst and anxiety!!
5. Loosely install hdr to exhaust studs....new gaskets!!!....# of which TBD.....anti-seize on studs.
6. Apply ultra copper RTV exhaust sealant on hdr/rsp collector flange...liberally and circumferentially and engage...remember you practiced this in step 3!!!
You got about 5 minutes to get this right before RTV starts to harden!!
7. Install lsp to rsp cross-over remembering to very liberally apply ultra copper RTV exhaust sealant to engagement. This connection is supported with a clamp.
Again........You got about 5 minutes to get this right before RTV starts to harden!!
8. Selective tightening.....depending on the results of steps 1 & 2....let me know and I will put together a torque sequence for you but basically will be center flange alternating between #1 & #3 flange.
Many small steps of tightening following a sequence. Don't forget to add the SS washers else the dome nuts will bottom before final torque setting can be achieved.
9. Install OEM O2 sensor.
============================
Also as Barty noted, remember that the Jardine exhaust brackets mount on the 'inside' of the footpeg holes and not outside. I had to refit the exhaust pipes again because of this goof up.
Remove OEM exhaust--------all you---Good Luck.
There are three (3) fundamental elements of the Jardine:
Header Manifold (hdr) that attaches to engine block exhaust ports.
Right Side Pipe/Collector/Muffler/Cross-Over (rsp)
Left Side Pipe/Muffler (lsp)
Before you actually install there are some "dry fit" steps I encourage you accomplish.
1. hdr to block flatness, alignment & registration.
Place hdr exhaust flanges on a flat surface (marble counter top works great) and check for flatness of hdr flanges.
All 3 flanges should be flat against surface simultaneously. Looks for gaps in say one flange and surface when two other flanges are gapless.
If any gaps are present and they are less than approx .060" we can fix by selective torque-ing to block and or the use of multiple gaskets.
Leave OEM exhaust gaskets in-place for now.
Place hdr on block studs and check for center-to-center registration of respective hdr flange to block exhaust port.
Each flange should engage the machined & gasket-ed block exhaust port equally, circumferentially, easily and simultaneously!!
I pray that this step yields good simultaneous registration else we have got our work cut out for us!!!
2. hdr and rsp collector flange circularity.
This is done on shop floor without either part attached to bike.
This interface is a line-to-line fit which can easily go astray!!
This is also the most important fitment for the ultra copper RTV exhaust sealant.
Engage the hrd and rsp collector flange so that full engagement to mechanical stop is achieved.
Now rotate the two elements at least two revolutions both CW and CCW.
Rotation should be relatively free of binding and will also remove any "high-spots" impeding good circularity between elements.
High spots will be identified by metal scoring...repair as necessary...it's real important when final assembly is done!!!
3. practice installation of hdr & rsp...let's you know what you are in for!!
The trick is to familiarize yourself with the gymnastics necessary for effortless (not really) install.
This is important because you will only have about 5 minutes of time after application of ultra copper RTV exhaust sealant to collector flange before it starts to set-up!!!
4. Loosely install heat shields to hdr...trust me!!..it may sound strange but will save you much angst and anxiety!!
5. Loosely install hdr to exhaust studs....new gaskets!!!....# of which TBD.....anti-seize on studs.
6. Apply ultra copper RTV exhaust sealant on hdr/rsp collector flange...liberally and circumferentially and engage...remember you practiced this in step 3!!!
You got about 5 minutes to get this right before RTV starts to harden!!
7. Install lsp to rsp cross-over remembering to very liberally apply ultra copper RTV exhaust sealant to engagement. This connection is supported with a clamp.
Again........You got about 5 minutes to get this right before RTV starts to harden!!
8. Selective tightening.....depending on the results of steps 1 & 2....let me know and I will put together a torque sequence for you but basically will be center flange alternating between #1 & #3 flange.
Many small steps of tightening following a sequence. Don't forget to add the SS washers else the dome nuts will bottom before final torque setting can be achieved.
9. Install OEM O2 sensor.
============================
Also as Barty noted, remember that the Jardine exhaust brackets mount on the 'inside' of the footpeg holes and not outside. I had to refit the exhaust pipes again because of this goof up.
