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Removing
the stock exhaust:
Before
we can remove the cylinder to install the big bore kit, the
exhaust system must be removed.
This
is a simple process, the pipe is held in only three places. The
front of the exhaust is held on by two springs which are
easily removed by using a proper spring puller tool (see
picture 1). These tools are available at auto
parts stores for working on drum brake set ups and are usually
very inexpensive.
The
middle and rear of the exhaust system are held on by M8
bolts which are removed by using a 6mm Allen key wrench. The
middle bolt is underneath the bike (see
picture 2). The rear is the exhaust hanger bracket.
These bolts go into rubber dampeners, but do occasionally
need to be held from the back side by a 13mm box end wrench. Try
not to damage these dampeners, as they will keep your pipe
from stress cracking as time goes on.
Now
that all the fasteners are removed, the exhaust will still
be attached to the cylinder because it slips in to the cylinder. Pull
the exhaust away from the cylinder and twist it at the same
time, this part can seem like it will take forever, but
it will eventually come loose.
Reinstallation
of your new pipe will follow the same procedure in reverse.
Tip: When
installing a new pipe, it helps to lube the header pipe
with a bit of two stroke oil to allow it to easily slide
through the o-ring inside the cylinder.
Proceed to Step
5: Removing the Head, Cylinder, Wristpin, and Piston
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