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It's a pretty straight forward install.
As for the existing system, I left all hoses connected, but the oil and coolant radiators need to be moved away from the engine. I used a couple of bungees and hung them from the lower triple clamp. Taking a couple of photos prior to disassembly of this area helps as they are kind of all supporting each other.
With the Zard you only have 3 header pipes and they are pretty different from each other bend wise, so It takes a little trial and error, but they fit into the 3:1 collector pretty well. I put them together first (without the springs, I put them all on at the end.) and hung them loosely from the exhaust ports. Remember, they all collect onto the bottom right (Brake Pedal) side of the engine.
The can went on a little hard on mine as the inlet was a little out of round. Nothing a pair of long neck pliers with rubber coated teeth couldn't solve though. With a little patience, it went on. The bracket for the can mounts behind the foot guard, and they supply a shim for the bracket hole that you don't use so it all stays flush.
The exhaust sensor wire needed to be rerouted on mine due to length issues. There is a quick disconnect on the right side under the tank behind the side panel to help this process. I rerouted the wire between the engine and swing arm and then had the necessary length to fit it into the Zard.
Don't push everything in all the way and tighten things down until you have the whole system together. It needs a little massaging to be sure nothing is rubbing. Now you have it all together put the springs on and slowly tighten all things down at the same rate, a little at a time.
It's a very good quality system in my opinion and you are going to enjoy it. I had to have my dealer load the TOR #20102 map to stop the popping created by the freer breathing engine.
Good luck.
[ This message was edited by: Shnel on 2006-04-15 21:44 ]
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