Pipe Installation Note: In most cases Rocket Exhaust systems will be installed on bikes that have been ridden a few times and or have fallen over once or twice. Point being the subframe has most likely been bent and not even the stock pipe fits correctly. We have designed in two adjustment features that allow for the pipe to be held in place with minimum preload and aligned properly, greatly reducing stress crack failures. First, the mid-pipe to silencer junction in the form of a rotating slip fit allows the silencer hanger bracket to rotate as needed towards or away from the subframe mounting point. Secondly, the silencer hanger bracket has over a half inch of movement simply by loosening two allen bolts allowing it to lay flat on the upper subframe mount. Details are in the pipe installation instructions below. It’s very important to follow these instructions to insure long pipe life and no air leaks. Tools usually required are 8mm, 10mm and 12 mm T-handles or sockets and 5mm and 6mm allen wrenches.
Remove any side panels that are in the way to gain access to the stock exhaust mounting locations.
Loosen the head-pipe mounting hardware for a slip-on installation. Remove the head-pipe mounting hardware for a full system installation. Take care not to loose the head pipe gasket. You’ll need it later.
Remove the mid-pipe mounting hardware, usually located near the kick starter and or on the lower part of the subframe. Also loosen any clamps that might be connecting the mid-pipe to the head-pipe.
Remove all the mounting hardware that holds the muffler assembly to the subframe.
Install the Rocket Exhaust head-pipe or in the case of installing a slip-on, leave the stock head pipe on but finger tighten the head pipe mounting bolts. Don’t forget the gasket. We recommend replacing the head-pipe gasket with a new one. Leave the head pipe finger tight so that it can be adjusted later on.
Apply medium strength high heat Loctite #246 thread locker, or similar product, to the three bolts that hold the mid-pipe to the muffler assembly and finger tighten them assuring that you can still rotate the silencer and mid-pipe at the flange junction.
Loosen the two allen bolts that hold pipe hanger bracket to the silencer can. Two turns is usually enough.
Fit the slip-on to the head-pipe and finger tighten the mid-pipe mounting bolt to the subframe, the three bolts that connect the mid-pipe to the silencer and the bolt that holds the hanger bracket to the subframe.
At this point the exhaust system is held in place at all the mounting points. Examine the fit and rotate the silencer at the mid-pipe junction to fine tune it.
Tighten the two head-pipe mounting nuts/bolts to the torque setting recommended in the owners manual.
Tighten the mid-pipe mounting bolt to the torque setting recommended in your owner’s manual.
Tighten the three bolts that connect the mid-pipe to the silencer. You may need to rotate the silencer again to fine tune the fit.
Tighten the two allen head bolts that hold pipe hanger bracket to the silencer can. Take care to align the bracket so that it lays flush on the subframe.
Tighten the bolt that holds the hanger bracket to the subframe to the torque setting recommended in the owner’s manual.
Reinstall side panel and enjoy.
Spark Arrestor and Spark Arrestor Stealth Core Installation
Screen type Spark Arrestor and Stealth Core Spark Arrestor are USDA/USFS Qualified. S1-Y787-01.
Remove the three allen bolts holding the end cap to the silencer assembly.
The end cap, nozzle plate and nozzle will fall off in your hand.
Install Spark Arrestor or Stealth Core with the screen pointed inside the silencer.
Reinstall the nozzle, nozzle plate and end cap and tighten the three allen bolts.
Please note that this is a high performance lightweight product and requires routine maintenance and proper installation.