hey guys, I just purchased a Danmoto slip-on exhaust and figured that since it didn't come with any directions of how to install it, as well as the baffle, I'd take the liberty of writing up a how-to. Danmoto Carbon GP Slip-on exhaust 2011 ZX-6r Install Disclaimer:
Neither myself nor zx6r.com are reliable for anything that goes wrong in your installation. If any part of this how to seems out of your league you're better off getting help or finding someone else to do it. Tools needed for exhaust installation:
Socket Wrench - 8mm socket
Allen(Hex) Key - 5/32"
Security Torx (has a hole in the center) - T25 (or 8mm socket for older servos)
Pliers or Vice Grips
Utility Knife or ScissorsTools needed for baffle installation:
Dremel with metal grinding/sanding attachment
Piece of wood
Your kit should include the following:
- 2 springs
- a long thin piece of metal with white tape on over the finished side and 2
- holes in it
- rubber as long as the metal piece
- the exhaust
- extension pipe
- baffle (if you ordered it).
(the extension pipe is backwards in this pic, the bend should be at the exhaust) Step 1:
Remove the aluminum cover that runs the length of the stock exhaust.
Remove the aluminum cover that covers the cat. Step 2:
With your 8mm socket, loosen (don't remove) the bolt that tightens the clamp around the stock exhaust. The bolt head is located more so underneath the exhaust, so get on the floor.
Again, with your 8mm socket remove the bolt that holds the exhaust to the passenger foot stay. You may need to use the 12mm wrench to hold the nut that is on the inner side of the stay. Step 3:
Pull back the textured plastic trim that is located under the gas tank and runs under the seat. You shouldn't have to remove it completely, just be careful.
With the allen key, remove the bolt that holds the seat on. Repeat for the other side and lift the seat off (gas tank side first). Step 4:
You should now see the servo motor.
With the torx wrench, unscrew the torx bolt and pull the metal piece off.
Now pull the cables out of it.
When putting the metal piece back on be sure to line it up correctly. Screw the bolt back in, be careful not to over tighten it or you will grind the servo's gears (if you plan on using a servo-buddy you can just remove the entire servo now - note doing this without a servo-buddy installed will cause the FI light to come on
Use the flathead to pry the bracket holding the cables in place.
Feed the cables through the frame and pull the exhaust off. You'll have to get the cables through a little hook located behind the rear brake stay. Step 5:
In this step we will install the baffle into the danmoto exhaust. If you are not installing the baffle you may skip to step 6.
The baffle that comes with this exhaust is meant to be a very, very tight fit. It's almost as if it's not supposed to fit.
The baffle goes in where the exhaust meets the extension pipe. Depending how clean the welds in your exhaust are, you may or may not need to grind down the inner welds with the dremmel (I had to touch up a small spot).
Once you are satisfied the welds are clean enough, grab a piece of wood that fits the baffles diameter and a hammer (or mallet). Time to bang that sucker in there until the baffle sits flush to the welds and is tight. I recommend flattening the box the exhaust came in and hit onto that so you don't ruin the exhaust tip. Step 6:
Time for the next tight fit. Slide the straight part of the extension pipe into the exhaust output (the cat). Fit it so that the bend is facing down.
Now you are going to have to force the exhaust over the extension pipe. They are very close in diameter so it may take some time and cursing to get it on there, but trust me it fits. Make sure you have the exhaust hooks/loops lined up with the ones on the extension pipe. Step 7:
Hook the springs from the exhaust side hook/loop and stretch them to the extension pipe hook/loop. This will take a considerable amount of force, so if you have good hand strength you can use pliers for this step, if not, use vice grips. Step 8:
Now it's time to mount the exhaust to the passenger stay.
Grab that long thin piece of metal, and peel the white tape off of the finished side. Fit the rubber gasket/guard/whatever you want to call it, from bend to bend on the non-finished side of the metal. It may be a bit longer so you may need to trim it up.
Wrap it around the exhaust and slide the bolt through the meeting ends on the outer side of the passenger foot stay. Tighten the bolt up. You'll prolly have to use the 12mm wrench on the nut to keep it from spinning.
Congrats! You have successfully installed a danmoto exhaust!