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Need advice with reinstalling factory exhaust

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1.2K views 5 replies 2 participants last post by  B0rn2ride  
B
#1 ·
Hi Everyone,

I bought a brand new Vulcan 900 Custom 2014 with the Cobra Speedster Swept installed from a bike dealer. The bike also have the Baron lowering kit. I like the sound around town and city but the highway too much for me. I asked the dealer for the original exhaust which they did give them to me. the pipes were wrapped in newspapers but the wrappings are completely different (black tapes vs clear tape, one appears to be very old and yellow from old age). They do look newish. They said they had several dozen pipes in the storage room. I took off the Cobra pipes and can't align the pipes mounting bracket to the bike support bracket with the header inserted the engine block. I need another 1/8" for one bolt and little bit over 1/8" for the second screw. I tried for a hour with no luck. The lower pipe seems to line up. I am attaching pictures without the bushings so you can see the mounting bolts. I thought Kawasaki Vulcan 900 didn't change much years. I emailed the dealer with the same info and see what they think.

1. Are the pipes the same for the 900C and 900 classic?
2. Are the pipes the same for each year?
3. Did they give me the wrong pipe or support bracket?

Any suggestions? any feedback would be greatly appreciated.

Thanks!
 

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#3 ·
Both custom and classic show same part number for the mufflers (18087) but are followed with an a,b, or c. So don't know if there is really any difference other than the covers.

To get any exhaust to line up you need to attach the bolts on the manifold first. I always use antiseize on the studs. Just barely put all 4 nuts on the studs. Maybe one full turn.
Then line up the pipe at the back with the bracket. Sometimes you have to pull or push the pipe to line it up. Start all bolts in the frame bracket but only a couple of turns.
Then torque the nuts on the manifold and lastly the bolts at rear on the frame.
 
#5 ·
No. Antiseize is a silver or copper paste that can withstand high temps and not melt off.
Due to the heat coming from the engine it is not uncommon for the manifold studs to rust and gall up, making it very difficult to get the nuts off without breaking the studs, after they have been on for years and never removed. Antiseize prevents that.

I see from your pic that the 900 has true duals so yes putting them on one at a time is best.
 
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