Triumphrat

PITTSBURGHRIDER · 07-29-2005

I have undid all screws? nuts etc. now do i just pull the front out or is there more to it. Don't want to force anything but is in there snug? Taking off to wrap headers with black exhaust wrap. Thought they would be much easier to wrap off.

RedBird · 07-29-2005

From my Service Manual for Bonneville/T-100:
1. Remove both silencers.
a. Slacken the clamp securing the silencer to the header pipe.
b. Slacken and remove the nut and washer from the rear passenger footrest.
c, Withdraw the passenger footrest and remove the silencer from the motorcycle. Recover the rubber washer, shouldered collar and mounting rubber from the silencer mounting bracket.
2. Remove the right hand side cover.
3. Unscrew the bolts and remove the sprocket cover from the engine.
4. Remove the cap and slacken the swinging arm outrigger clamp bolt on the right side rider footrest bracket.
5. Unscrew the right side footrest bracket mounting bolts and the rear brake master cylinder mounting bolts.
6. Free the footrest bracket from the swinging arm outrigger and position it clear of the header pipe mounting bolt.
7. Slacken the clamp securing the header balance pipes together.
8. Unscrew the nuts securing both header pipes to the cylinder head.
9. Unscrew the mounting bolt from the rear of each header pipe.
10. Free the header pipes from the cylinder head, separate the balance pipe and remove both pipes from the motorcycle. Recover the rubber mountings from each header pipe rear mounting.
11. Remove the gasket from each cylinder head port and discard them. ( You will install with NEW gaskets if you want it to not leak.)

This procedure works--I have removed the headers on my '03 T-100 a couple of times. I don't know of any short cuts. Installation is a little more difficult because of the balance pipe.

Good Luck,
Larry

PITTSBURGHRIDER · 07-30-2005

thanks redbird.

ssjones · 07-30-2005

Reinstalling the balance pipe is a bit fussy. A 2nd pair of hands would make it easier.

PAAS · 07-30-2005

Quote:

On 2005-07-29 20:26, RedBird wrote:
From my Service Manual for Bonneville/T-100:

8. Unscrew the nuts securing both header pipes to the cylinder head.

In true service manual fashion it tells you what to do but not how to do it. Maybe I'm missing something but I haven't been able to get a socket and driver in there to undo the nuts as the frame and oil cooler get in the way. What tools do you use to get at the nuts? I've considered temporarily moving the oil cooler out of the way but would rather not if it's avoidable.

Thanks,

Paul.

07-30-2005

The only problem I had was that I had to use a big flat head screwdriver to pry the crossover pipe down somewhat to get clearance for the head bolts..

RedBird · 07-30-2005

PAAS,
I used 3/8" drive sockets and ratchet. I used a 12 point, 12 mm socket (I prefer 12 point over 6 point in tight places), a 1-1/2" extension, and a ratchet that has the large reversing "lever" on the back-side. A ratchet with a small "reversing" lever on the front side would give you more clearance, and I always recommend this type over the cheaper ones with the larger reversing "lever" on the back side.
Now, torquing upon reinstallation is quite another story; but, I did manage to torque each nut without any damage to the oil cooler.
On reinstallation, don't forget to use some clear silicone on the new header gaskets--it also works nicely to hold the gaskets in the head--yes, I got the blasted stuff all over my fingers as usual, but it was worth it. :-D
Larry

RaceDweeb · 07-30-2005

Soak the heat wrap in water before wrapping. It will wrap tighter and look much better. And wear gloves!