by Jim » Fri Jan 08, 2010 9:46 am
I have found that the easiest way to fit these exhausts is to-
-Remove rear footboard (kick start side) also remove the kickstart and the lower retaining nut on the rear suspension. Also loosen but don't remove the cylinder cowl, and remove the U pipe.
-Completely assemble the exhaust away from the scoot, ie- place the chrome megaphone on the pipe on the box, and insert the U pipe into the exhaust, and roughly line everything up to what looks like the correct positions but with the U pipe rotated slightly lower than it should be, but don't tighten up either of the clamps.
-Offer the whole exhaust into position, ie- the exhaust box bracket onto the 2 retaining bolts and at the same time, the megaphone bracket onto the suspension bolt. Replace retaining nuts, but not completely tight. Now swing up the U pipe onto the exhaust port (don't forget the gasket!) and tighten up the 2 retaining bolts and nuts.
-Re- secure the cylinder cowl, tighten up the exhaust bracket retaining nuts and the clamps and tighten up the large retaining nut on the lower suspension bolt.
-Replace rear footboard and kickstart and check to see if the kickstart misses the exhaust when operated.
I've found that it's very difficult (if not impossible!) to install this exhaust on a U pipe that is already on the engine- I think this is where the horror stories might come from! Also it's tricky to fit the megaphone onto an installed exhaust box. Gasket glue can be applied to all joints during instalation if you want to do a really good job, and the use of a torque wrench ensures the correct tightness of nuts. Hope this helps!
Jim