Author Topic: Assembly Order for Exhausts Footpegs & Brake  (Read 370 times)

Offline Colsbeeza

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Assembly Order for Exhausts Footpegs & Brake
« on: 21.09. 2021 10:08 »
I've been caught yet again on the S/A Flash.! *problem* I am sure most of us have done the same.
I put the exhausts & mufflers on first, but they prevented me from getting the footrest long bolt through, so off came the exhausts again. Another hour later, I finally got the order right. I have a front crashbar, and the exhaust mount bracket fits behind the crashbar bracket (1st picture). So removing the exhaust pipes gets complicated. I have to undo the top crashbar mount, remove a nut from one end of the long bolt, slide the bolt through the exhaust and crashbar brackets, remove the exhaust pipe and then do the same for the other side.
I've done this before, but failed to check my notes from back then.
So here is my procedure which may be helpful for others.
Final Correct Order of assembly - hopefully now locked into brain.
1. Install footrest long bolt and tighten nuts - no access to nuts when exhaust pipe is on (2nd picture). I use 3/4" SAE spanners which I think are original, a ring on LHS and Open end on RHS, as the ring won't fit.
2. Install exhausts and mufflers - go through the crashbar saga in reverse.
3. Install brake crossover and splined cable arm. Connect return spring on LHS
4. Connect rear brake cable and do adjustments.
I have now added this to my assembly check list so won't forget next time.
Col
1961 Golden Flash
Australia

Online Roger (Doomtrainbarx)

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Re: Assembly Order for Exhausts Footpegs & Brake
« Reply #1 on: 21.09. 2021 12:00 »
By coincidence, I've just fitted new standard front pipes to my SR and got rid of the bad fitting sweptbacks.
I still have full access to the footpeg  mounting bolts which I can remove even with exhausts in situ.
To remove primary side peg I detach the stop light switch spring and the rear brake cable clevis pin - then I can depress the brake pedal enough to remove the footpeg. - I guess all pipes aren't the same ?
1962 Super Rocket
2003 Kawasaki Z1000
1987 Kawasaki ZL1000 Eliminator
1989 Harley FXRS (Turbo)

Offline Colsbeeza

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Re: Assembly Order for Exhausts Footpegs & Brake
« Reply #2 on: 21.09. 2021 13:36 »
Roger, I can't remember where I got the pipes from, but I had to cut about 3/4" from the head end of the pipes, and bend the brake pedal out about 1/2" to clear the pipe on LHS. I am certain that all pipes aren't the same.
Col
1961 Golden Flash
Australia

Online Roger (Doomtrainbarx)

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Re: Assembly Order for Exhausts Footpegs & Brake
« Reply #3 on: 21.09. 2021 15:57 »
Col
Photos may or may not help you - my left front pipe also has a slight kink just before the silencer joint.
1962 Super Rocket
2003 Kawasaki Z1000
1987 Kawasaki ZL1000 Eliminator
1989 Harley FXRS (Turbo)

Offline Colsbeeza

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Re: Assembly Order for Exhausts Footpegs & Brake
« Reply #4 on: 21.09. 2021 23:41 »
Roger,
It looks like my pipe sits higher than yours, so that it interferes with the spanner on the footrest nut.
I'll check my records to see if I can find the source of the pipes.
Col
1961 Golden Flash
Australia