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6th Gen Stock Exhaust Removal / Staintune Installation


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  • Member Contributer

Note: There are several versions of the mid-pipe for the 6th Gen Staintune exhaust. The hanger and shape may differ.

Note 2: If your Staintune exhaust is second hand, inspect the hanger mount-point on the mid-pipe for cracking. This is a common failure point and Staintune will repair/replace for free, or you can have a local welder take care of it (voids warranty).

Note 3: Some Staintune systems for 6th gens are one piece. You can follow this guide, just know your mufflers are pre-attached.

 

Remove Seat

 

Disconnect license plate light connector.

BB4oTGw.jpg

 

Remove four 10mm bolts. Bolts closest to the rear can be tight, gently pull upward on the light to provide better access.

v93F03N.jpg

 

Remove two 12mm bolts.

fVqi0Wq.jpg

 

Pull license plate wire out of under-seat compartment.

 

Remove license plate/light assembly.

 

Loosen exhaust clamp.

xwfPRUT.jpg

 

Loosen muffler hanger bolts.

qxuzLhE.jpg

 

Both have 13mm nuts under the seat.

0NnbapP.jpg


Remove both hanger bolts. Be careful when removing the last bolt, as the exhaust will be able to drop down to the tire.

gV5wuPP.jpg

 

Gently swivel off the exhaust, and remove.
X40Y2kU.jpg

 

Remove the OEM lead gasket from the outlet pipe on the catalytic converter, as this is not needed. Wash your hands.

anViZkN.jpg

 

 

Take a well earned beverage break and marvel at how heavy that stock exhaust is!

 

Now, let's install the Staintunes!

 

 

Remove rear most bolt on the right passenger foot-peg.

IpWMlhp.jpg

 

Mount the Staintune mid-pipe, noting alignment with that passenger foot-peg bolt hole.

rZb9cwV.jpg

 

Install provided longer bolt and nut to the passenger foot-peg. If you need one, it's a M8x55-1.25 bolt and matching nut.

Lz42P9x.jpg

 

I replaced the other three passenger peg bolts to match since they were not a hex type. (M8x50-1.25, (2) M8x30-1.25)

gwd9AfY.jpg

 

Tighten the exhaust clamp.

Nuu8NQj.jpg

 

Slide the left muffler onto the mid-pipe, and install / tighten the previously used hanger nut and bolt. Staintune text should be facing the outside of the bike.

dkfgkMm.jpg

 

Do the same with the right muffler.

W55T4B1.jpg

 

Feed the license plate light wire back into the under-seat compartment.

 

Reinstall the two 12mm bolts.

fVqi0Wq.jpg

 

Reinstall the four 10mm bolts.

v93F03N.jpg

 

Reconnect license plate light connector.

 

Reinstall the seat, start the bike, and enjoy!

 

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  • Member Contributer

Hongsta - are you replacing your aftermarket system, or just servicing it? I'm on the lookout for a used aftermarket system for my friend's 2002.

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