Exhaust Installation

I have read and heard many opinions on how to properly install the headers and peashoots on a commando. I recently purchased new Exhaust Nuts, Rabers Conical Headers and Stainless Steel no seam Peashooters for my 1974 850.

I have installed and honestly distroyed many sets of headers over the years because i didn't install them properly causing them to not set right and brake.

Before I install these any tips, tricks or suggestions will be appreciated.

Thanks!

Headers ? It is usually the front weld on the muffler that breaks for me.

My suggestion is to let the exhausts go where they want to go. I push the headers in towards the center of the bike so the kickstart clears the pipe. Add the mufflers and either shim or use thinner rubber bobbins (RGM) to make the mountings line up. Once it is in place and lined up, start tightening everything in stages. I got the system hot before I really reefed on the exhaust nuts. Then hope that it stays where it wants to be.

I've got about 4000 miles on a new Toga exhaust and so far so good. YMMD.

Greg

Also, I'd suggest:

Good exhaust header crush gaskets. I like those made for Suzuki GS 750/1000.

Antiseize on all threaded parts, particularly the exhaust nut threads. Torque exhaust nuts to 60 lbs-ft.

Tighten from the front back (exhaust nuts, then header-to-muffler clamps, then muffler to frame connections).

Get hot and while still running (ideally, with a friend revving to 3-4K RPMs), retorque exhaust nuts. Turn off and check other connections and retorque as necessary.

Repeat last step for the first few heat cycles.

Enjoy.

One hint I'll give is after everything situated and you need to pull the head or or anything requiring exhaust removal, take the whole system off as a unit. Saves the exhaust threads!

I assemble the exhaust system loosely then do the final setting and lock down with the bike off the main stand and preferably someone sitting on it. That way it's stress free when ridden.

Works for me.

Cash

Thanks for the suggestions guys.

I will be doing the install tomorrow. Much appreciated.