2023-12-08 KZ1300 DG 6-1 Exhaust <Almost> Installed

2023-12-08 KZ1300 DG 6-1 Exhaust <Almost> InstalledBeen dreading this moment. Ray had told me what a PITA it was to stab all six headers into the collector.
Yet here we are.

Making it worse, the CermaKote process added thickness to an already too tight fit. Used a Dremel to reduce OD at slip joint and header flange area.

Brand new exhaust gaskets.

Not as shiny as chrome. But most of it is hidden anyway.. Radiator, fan, etc. These have sitting outside for about 6 months..
Some of the shine has diminished over time.
Cleaned fingerprints off using lacquer thinner then donned gloves to install. Oil from fingerprints etches
the CermaKoat when heat is applied.

Turns out the collector and header pipe are marked with cylinder number. 
Install order is 1 - 2 - 3 - 4 - 5 - 6.

Got all the way here, got the exhaust gaskets in place, used a rubber mallet to 'seat' everything...Then discovered I forgot the 'collars'. Acck.  

2023-12-09 Kz1300 Exhaust Finally InstalledHoping I never have to do this job again.
Fitting all the collars and gaskets, while trying to wiggle everything into place.
With arthritic fingers.. truly a PITA.

..and I ended up scratching the headers too. Acck.

Late afternoon sunlight is perfect for engine porn pics.Hopefully it's all sealed up correctly.. no pffft pffft leaks.

Looking forward to fan mod and install.

Lo

 

That looks like a mission, i have a D&G still in the box that i brought for when my exhaust finally rots out hopefully i will put it off as long as possible

paulb wrote:

That looks like a mission, i have a D&G still in the box that i brought for when my exhaust finally rots out hopefully i will put it off as long as possible

I can't recommend the DG. The fit isn't precise, especially at the rear mounting point. There's a bit of 'tension' at that mount point. And, you have to remove the shocks to change the rear tire or, worse, remove the muffler.

Rather, I'd keep the stock dual walled headers and put some Busso's on. My .02 FWIW.