Header came loose...

[delvryboy]

So, like copper terminals that have 2 bolt holes?

[yamaha_george]

So, like copper terminals that have 2 bolt holes?

Yeh sort of you do not want copper ones but steel ones (copper will not last 10 mins as the springs will vibration cut thro them )

[delvryboy]

I'm going to pick up the springs tomorrow. Should I use something like throttle return springs, or something heavier?

[thatkid]

Finally got them. They should look like this. And they should be heavy duty. To get them off takes a serious grip on some pliers or vice grips locked on and pulling hard. Too weak and they won't hold the pipe on.

[yamaha_george]

Finally got them. They should look like this. And they should be heavy duty. To get them off takes a serious grip on some pliers or vice grips locked on and pulling hard. Too weak and they won't hold the pipe on.

TK,
I notice your spring end just goes over the flange. Do the flanges have alip to hold the end of the spring or a hole ?
Just curious as all the race systems i have used / seen had the tab washers I talked about .

[thatkid]

There is a hole that the spring goes through.

[delvryboy]

I'm about to head out now, I'll check for holes in the flanges.

[delvryboy]

No holes. I got some springs, I just have to figure out how to hook them up top. I'm thinking over-sized washers and slide them to one side.

[delvryboy]

Any thoughts on using an exhaust epoxy for the pipe>coupler? The flange would still float free.

[yamaha_george]

No holes. I got some springs, I just have to figure out how to hook them up top. I'm thinking over-sized washers and slide them to one side.

That or drill the hole in the flanges ????????????

[reelrazor]

If you know you have springs that will make it, you can bend a right angle sideways (vise and hammer) to the 'hook' end of the spring and then trap that under a bolt head (use IT as a washer-put a normal flat washer on top of the hook.

From this:

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To this:

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[sweekster]

That or drill the hole in the flanges ????????????

I was thinking the same thing

[delvryboy]

I'm sure there is some good reason to use springs, however, I welded the couplers to the pipes. I wasn't happy with how I had the springs on nor the springs I found as well.

[yamaha_george]

I'm sure there is some good reason to use springs, however, I welded the couplers to the pipes. I wasn't happy with how I had the springs on nor the springs I found as well.

D,
I hope you welded (tacked at least ) while they were on the bike or they will not automatically line up ( Do not ask how I know this ) If you arc welded I hope you disconnected the battery & the TDI as they have a habit of going KIA on you shortly afterwards.

[delvryboy]

I tacked them off the bike. Everything lined up pretty good. :thank goodness: I thought about that after the fact. It was a real pain to get the pipes all the way up to the inner lip in the coupler, I doubt I would of been able to do it with the couplers already bolted to the head. I used a liquid exhaust manifold weld inside the coupler and then put a couple tacks per pipe. The couplers are a softer aluminum and I didn't want to burn them up.

I know though, it would of been a disaster had everything not lined up.

On another note, these pipes haven't been all the way in for a long time. It took me 30 minutes to get all of the carbon cleaned out from the inside of the couplers.