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Search the Community: Showing results for tags '6th gen exhaust'.
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Hello all - I have successfully mounted a newly ceramic coated set of 1998/1999 catless headers to my friend's 6th gen. I have unsuccessfully mounted a stock 6th gen canister assembly to the 98/99 headers. [We will be installing a Power Commander V, so will not require 02 sensors or associated bungs] Sorry I don't have photos yet, but I'll be able to post some by this Saturday. The 98/99 headers have a couple minor dings from their life before the ceramic coating, but nothing major. I do not know their history. After aligning the stock 6th gen exhaust canister assembly to its mounting points, it is 5mm too high, 15mm too far left, and rotated a tad so that the support bolts wouldn't line up even if position was correct. This is the same stock 6th gen canister assembly that earlier fit the stock 6th gen headers on this motorcycle with no problem, so I suspect the new used headers are the cause of the problem. I have used all new OEM copper crush washers and all new OEM exhaust sleeve gaskets and have torqued the cylinder exhaust studs very gradually and evenly to their specified torque. Having read MVinOZ's thread here and seeing how much bending of exhaust he did with leverage and force, I attempted to use some leverage of my own to persuade the canisters to move into place, but stopped when I thought more force might sacrifice a cylinder stud. Does anyone have a suggestion for getting the headers and canister assembly to line up when the components prefer to misbehave? The motorcycle's owner suggested heating to bend via running the engine or using a butane torch. To me, it didn't seem the engine would generate enough heat that far back in the exhaust system to help persuade the exhaust. I am researching whether direct application of a high heat flame [Like a torch] would be detrimental to the ceramic coating. Thanks for any assistance!