I installed the top end so now I can install the header pipes I refinished and the new Sito exhaust I bought from Motobins in the UK. I bought the pipes with the “bullet end” style used with the /5 series.
You can read about how I refinished the headers here:
Here is the parts list for this work.
|07 18 R kit 002 SS||Muffler mounting bolt kit
[Hucky's Part #]
|88335||Sito /5 “bullet” mufflers, pair
[Motobin Part #]
The Invoice from Motobins which included my personal customer ID card. That’s unique. Even with shipping, the price seemed reasonable compared to new mufflers from BMW.
Here is the Sito muffler pieces I received. The shipment included the two mufflers and mounting hardware for attaching mounting brackets to the muffler body.
I had the header nuts bead blasted. I use anti-seize on the threads in the heads to prevent thread galling.
Here is the header pipes that I cleaned up to remove the bluing and 40 years of crud. The cross-over pipe is new as the original was badly pitted from gravel. The plastic bag has the new stainless steel Allen head bolts that attach the muffler to the frame.
The headers are sealed in the head using two steel rings each with a flat and beveled side. One ring is split.
Install Header Pipes
I put anti-seize on the threads of the header spigot and then put the header nuts on by hand. I check to be sure the nut goes on smoothly with no binding. This helps spread the anti-seize on the threads as well.
I put the header nut and then the steel rings on the header pipe. The split ring goes on last with the flat side facing the header. The other ring is next with the bevel side facing the bevel side of the split ring. I put a thin layer of anti-seize on the outside of the header pipe.
I insert the header pipe into the spigot in the head and push it so it is seated all the way inside the spigot. I hand tighten the header nut so there is a bit a drag on the header pipe, but I don’t tighten all the way as I need to adjust the header to align the cross-over pipe and the mufflers. I keep everything loose going from the front to the back of the bike, and then I tighten all the connections going from back to front.
I install the other header pipe and then I add the cross-over pipe between them. There is a clamp that holds an Allen head bolt and a nut and washer that tighten the cross-over pipe to the stubs on the header pipe. In the picture, these are shown on the bottom, but the final orientation is on the backside of the cross-over pipe facing the engine so the the Allen head bolt and nut are protected. I keep the cross-over pipe loose enough that it turns on the header stubs so I can position the header pipes when I install the mufflers.
The bracket mounts to the muffler body. It has slots cut into it to help align the mufflers on the bike and the brackets on the frame mounts. The bracket is oriented so the slots go across the muffler body as shown here.
The other slots are then oriented along the muffler and allow the muffler to be moved forward or backward on the frame brackets as shown here.
The ends of the mufflers slide easily onto the header pipes. The right side has a cutout on the bottom to clear the rear brake arm. There is a bracket with Allen head bolt to tighten the muffler onto the header pipe so I don’t use the stock BMW hardware.
I align the muffler bracket on the frame bracket and attach it with the new stainless steel Allan head bolts. Here is view from the bottom looking up through the muffler bracket to the frame bracket. Everything lined up nicely. I tighten the stainless steel Allan head bolts through the muffler bracket securing it to the frame.
I tighten the muffler-to-header ring Allan head bolt securing the muffler to the header pipe.
Then I tighten the Allen head bolt on the cross over pipe. Last, I use the header nut wrench and tighten the header nuts. The torque setting in some manuals calls for 145-159 FOOT/pounds. But Bob Fleischer says he feels this is too tight. He, like I, use the wrench and give a good “grunt” on the end of the header nut wrench. Bob estimates that torque is closer to 90 FOOT/pounds.
Wow. These are very nice looking exhaust pipes. I’m very pleased with how easy they installed and how well they lined up with the existing frame brackets.