I have only had my 15 for under 2 months so no experience taking it apart yet. Decided to install Black Widow header and Delkevic 18" Carbon Fiber muffler. Arriving this week. I have the factory service manual and found section on exhaust removal. For the muffler, it says only the saddlebag needs removed. I assumed for the header that the lower (black) fairings would have to come off. But it doesn't mention removing those? It says the front middle fairings, horn and radiator. But to get the front middle fairings off, it says to remove rear middle fairings. Those require the inner cover (the black area that holds glove box) to be removed. The upper inner cover requires removing the fuel tank cover. So essentially it is saying I would need to remove the fuel tank cover, inner covers, rear middle fairings, front middle fairings, horn, radiator, and since I have canyon cages those would need to come off too to get the rear middle fairings off. But doesn't say need to remove lower fairings. This just doesn't seem right? What all needs to come off? Don't want to waste time taking all this off if not necessary. But also don't want to scratch my bike up or break tabs on fairings if don't have enough clearance.
for the header nuts, what is best way to remove them. Warm bike up, then remove them? penetrating oil? I have more concern than most on this because about 20 years ago, I decided to sell my 1991 Suzuki Katana since it had become a track bike when I bought my 99 ZX-9R and when got married and had kids I didn't make any track events. I decide to remove the Vance & Hines pipe and take it back to stock before selling. Well, 4 of the 8 bolts snapped! The 4 on the inside cylinders. "these were steel bolts in the aluminum head, not studs/nuts like the concours. Not enough stud left to do much-about 1-2 threads. I drilled out 1 of them, but just kinda didn't have time with newborn and work and the thing is still sitting in my garage! Keep saying one day will get it running. carbs are in a million pieces.
Once exhaust installed, the ECU will be sent to Steve. Also will install the exhaust reducer in the mid pipe per Steve's recommendation. And after reading the old revived thread on Delkevic vibrations, will install rubber at mount and bolt in where baffle would go if needed. oh, that thread says that the Delkevic only mounts by the muffler hanger, but some of the pictures show a bracket welded to mid pipe? see large picture. maybe generic picture, not the actual concours kit? But the Black Widow mid pipe has same bracket (smaller picture). was there change since that thread?
for the header nuts, what is best way to remove them. Warm bike up, then remove them? penetrating oil? I have more concern than most on this because about 20 years ago, I decided to sell my 1991 Suzuki Katana since it had become a track bike when I bought my 99 ZX-9R and when got married and had kids I didn't make any track events. I decide to remove the Vance & Hines pipe and take it back to stock before selling. Well, 4 of the 8 bolts snapped! The 4 on the inside cylinders. "these were steel bolts in the aluminum head, not studs/nuts like the concours. Not enough stud left to do much-about 1-2 threads. I drilled out 1 of them, but just kinda didn't have time with newborn and work and the thing is still sitting in my garage! Keep saying one day will get it running. carbs are in a million pieces.
Once exhaust installed, the ECU will be sent to Steve. Also will install the exhaust reducer in the mid pipe per Steve's recommendation. And after reading the old revived thread on Delkevic vibrations, will install rubber at mount and bolt in where baffle would go if needed. oh, that thread says that the Delkevic only mounts by the muffler hanger, but some of the pictures show a bracket welded to mid pipe? see large picture. maybe generic picture, not the actual concours kit? But the Black Widow mid pipe has same bracket (smaller picture). was there change since that thread?
