So i have been wanting to do this for a while now. And just got the time to do it today.
I started off by drilling out the holes in the flanges that mount up to the cylinder head. I used a 13/32 drill bit. Worked out great. So once that was done i mounted up the header to the bike. I installed both nuts to the two outer pips and torqued them to spec so the the header would be sitting where it needed to be, without bind. Then i used a 1 3/4 to 2 inch adapter, i slid it into the GYTR and held the muffler were it would be mounted to see about how much of the 05 header i would have to remove. Witch just happen to be right behind the mount that holds the plastic away from it.
Then after that i held up the muffler with the adapter in it to match up the adapter to the header. I had to cut and grind it and to angle to match up and position the GYTR in the right spot to mount up correctly.
I then installed the bolt that holds the GYTR to the mount on the bike, and centered the adapter to the header. perfect fit. I then tack welded it in place. I also marked out were i was going to install the o2 bung. Witch i got form a local exhaust shop for fee. Then I removed the muffler, then removed the header to full weld the adapter in place. And to drill the header and weld on the o2 bung.
So after welding it up, i drilled the hole for the o2 sensor. I had to grind a curve into the bung so that it laid on the header the way wanted it to. Then welded it into place. After that i paint it real quick. Remounted it and made a rear hanger to help support the header in the rear. Re mounted the GYTR up and was done. Im going to take the bike to work and throw it on the Dyno to see how the WOT fuel is, if needed, witch i am sure it will, im going to install a PCV and tune it. It sounds great and looks good. Not bad for an afternoons worth of work and $50. Ill install the plastics once i get it off the Dyno and back home.
I also had the rear pegs and mounts powder coated matte black. And got those put back on as well. Next will be the fronts.
Let me know what you all think. This is my first write up.
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