K69 (2020+) Full Exhaust Install

[sdiori]

Hi All!

I picked up a full exhaust (muffler/silencer + headers/collectors) for my 2021 XR.

My search of YouTube revealed very few full install videos, though there are many of the R and RR.

Of those, it appears the install isn't necessarily the most friendly.

Would love to hear from those of you who have completed a self-install.  How was it? Any tips or advice?

I don't have a lift, so I'd be doing this "the hard way."

Thanks!

[SimonUK]

I have only done this on a GEN1, but I would imagine the process will be much the same. the biggest headache is getting all the plastics off and them noting/remembering what screw type goes where. 2nd potential issue is that the bike has to be off the center stand to get the guppy-belly exhaust off(just means you need buddy to hold the bike upright while you drop the OEM header unit). Tools that help immensely - spring puller, 10mm 12point long socket, patience. But it is perfectly doable.

[sdiori]

Originally Posted by SimonUK

I have only done this on a GEN1, but I would imagine the process will be much the same. the biggest headache is getting all the plastics off and them noting/remembering what screw type goes where. 2nd potential issue is that the bike has to be off the center stand to get the guppy-belly exhaust off(just means you need buddy to hold the bike upright while you drop the OEM header unit). Tools that help immensely - spring puller, 10mm 12point long socket, patience. But it is perfectly doable.

Thank you!

[CaptainSkinnyArms]

I just recently changed my headers out on my Gen 2.   There's a couple videos on YouTube I used to help me remove fairings.  I didn't need a lift when removing stock headers/cat.  I kept the the bike on the center stand,  remove side fairings, loosened the radiator and moved it forward for more clearance for header nuts.  I then removed the 8 header nuts, unplugged the O2 sensors ( make sure you take pictures of how the O2 sensors wires are routed).  I then removed the centerstand put the bike on the sidestand and lastly removed the last bolt holding the header and cats to the bottom if the bike.  Repeat process in reverse for installation.

[Hugg727]

I did this without a lift and it wasnt that bad.  I followed a few videos but this one stood out to me.

[esso_sa]

Originally Posted by sdiori

Hi All!

I picked up a full exhaust (muffler/silencer + headers/collectors) for my 2021 XR.

My search of YouTube revealed very few full install videos, though there are many of the R and RR.

Of those, it appears the install isn't necessarily the most friendly.

Would love to hear from those of you who have completed a self-install.  How was it? Any tips or advice?

I don't have a lift, so I'd be doing this "the hard way."

Thanks!

I installed (and removed) Akrapovis SS header on mine.
No lift, just a simple garage and laying on the floor 
The most important thing - get a spring puller tool. It will make things much easier

On gen 2 you need to remove both side panels. It is not that difficult, just a couple bolts and clips holding everything in place.
I kept both of my radiators in place. No need to remove them; even the oil cooler can stay bolted in its place. You just need to remove its supporting bracket since it goes between the header pipes. And use a piece of cardboard to protect the both coolers so you don't damage the fins.
I did everything with the bike on centre stand and when the headers were ready do go down, I put the bike on side stand, removed the centre stand, pulled the headers out.
You need to replace the exhaust gaskets. They are metal, crush type so if you re-use them you risk exhaust leak. It would be wise to replace the headers nuts too, but most people re-use them.
As for the O2 sensors - the front ones (widebands) will go down with the header, and they are easy to remove since you will disconnect their cables.
However, the rear ones (narrowbands) stay connected to the bike, so you need to undo them like that, which means that you will twist their cables. Be careful with this, so you don't break them. Especially the left one (behind the gear shift lever); that one is tight and there is not much room to twist the cable away enough from the sensor itself. Also, count how many turns it took to remove them, so you can pre-turn them counter clockwise before you bolt them in the headers - this way the cables will go back to normal position when you tighten the sensor and won't stay twisted.
Akrapovic says to hand tighten the flanges, install the headers, hook the springs and then tighten everything to final torque. In my opinion - this is impossible with springs in place. What I did is fit and hand tighten the flanges with the springs hanging, then slide the headers fully in the flanges, tighten everything to specified torque, then hook all the springs to the header pipes. Cylinders 2 and 3 will be the difficult ones, but it is manageable.
Then reinstall all the other parts and you are ready to go.
Also, before you start the bike, clean the headers thoroughly with some alcohol so you don't burn the hand and finger stains on them when they heat up. If you do, you will never clean them.
And leave the bike to run at idle for a couple minutes; sometimes it needs a minute to re-calibrate
It is a long post, but I hope it helps

[smithy]

Originally Posted by esso_sa

I installed (and removed) Akrapovis SS header on mine.
No lift, just a simple garage and laying on the floor 
The most important thing - get a spring puller tool. It will make things much easier

On gen 2 you need to remove both side panels. It is not that difficult, just a couple bolts and clips holding everything in place.
I kept both of my radiators in place. No need to remove them; even the oil cooler can stay bolted in its place. You just need to remove its supporting bracket since it goes between the header pipes. And use a piece of cardboard to protect the both coolers so you don't damage the fins.
I did everything with the bike on centre stand and when the headers were ready do go down, I put the bike on side stand, removed the centre stand, pulled the headers out.
You need to replace the exhaust gaskets. They are metal, crush type so if you re-use them you risk exhaust leak. It would be wise to replace the headers nuts too, but most people re-use them.
As for the O2 sensors - the front ones (widebands) will go down with the header, and they are easy to remove since you will disconnect their cables.
However, the rear ones (narrowbands) stay connected to the bike, so you need to undo them like that, which means that you will twist their cables. Be careful with this, so you don't break them. Especially the left one (behind the gear shift lever); that one is tight and there is not much room to twist the cable away enough from the sensor itself. Also, count how many turns it took to remove them, so you can pre-turn them counter clockwise before you bolt them in the headers - this way the cables will go back to normal position when you tighten the sensor and won't stay twisted.
Akrapovic says to hand tighten the flanges, install the headers, hook the springs and then tighten everything to final torque. In my opinion - this is impossible with springs in place. What I did is fit and hand tighten the flanges with the springs hanging, then slide the headers fully in the flanges, tighten everything to specified torque, then hook all the springs to the header pipes. Cylinders 2 and 3 will be the difficult ones, but it is manageable.
Then reinstall all the other parts and you are ready to go.
Also, before you start the bike, clean the headers thoroughly with some alcohol so you don't burn the hand and finger stains on them when they heat up. If you do, you will never clean them.
And leave the bike to run at idle for a couple minutes; sometimes it needs a minute to re-calibrate
It is a long post, but I hope it helps

Excellent write-up Sir..!! 

Sounds pretty much the same as my Gen-1 install, several years ago.

Smithy.

[sdiori]

You guys are all awesome.

Thank you!