How Do You Get The Front Header Pipe Off

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by dwj - Donnie, Aug 31, 2013.

  1. dwj - Donnie

    dwj - Donnie Long timer

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    Getting ready to change my Water Pump Seal and Shaft as PM on my 2007 990ADV. How do you get the front header pipe out? I thought it should come straight out, no! I took the screws off the heat shield and could not get the shield out! Which way do you turn the thing to get it out? I also noticed that there was one washer behind the plate holding the headed pipe in, should there be one on each side? I have had this moto since it had 4,900 miles and I don't think the header pipe has ever been off. The markings on the plate make it clear that there was only one washer. Thanks!
    #1
  2. Hootowl

    Hootowl Long timer

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    I will be interested to read the replies.
    I found it somewhat difficult to remove the pipe but even more so when it came time to install it. I got so frustrated that I had to walk away.
    My sweetie had a go at installing it, got frustrated and called a girl friend. Working together they got it lined up and I finished the install.

    I'm sure there must be a technique to do a R&R rather easily. I hope to learn that technique.
    Richard
    #2
  3. rossguzzi

    rossguzzi 990 Adv.

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    Its an intelligents test :lol3
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  4. folknride

    folknride Old Adventurer

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    Fail



    :rofl
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  5. folknride

    folknride Old Adventurer

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    Seriously (:evil), it's been a while, but I remember having to loosen all the exhaust connections, and remove the heat shield - then it's one of those annoying twisty puzzles - then suddenly it just comes out.
    Don't forget to get a new graphite gasket for the re-connect - you will almost certainly wreck the old one during disassembly.

    Have fun :wink:

    BTW - putting it back is fun too!
    #5
  6. nomad guy

    nomad guy A legal alien

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    You need to loosen the clamp that holds the header to the rear section. You might be able to do it without removing the rear plastic cover.
    After everything is loose, wiggle the header pipe until its clear of the cylinder studs.
    Then its just a matter of twisting the right way to get it out.
    There is no real reason to damage the graphite seal. When re-installing make sure to put everything in place before tightening any nuts or clamp.
    Make sure the the rear clamp is tight and there is no exhaust gas leak.
    Good luck.
    #6
  7. dmn0507

    dmn0507 Been here awhile

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    I've removed the heatshield, the lambda sensor and... the battery since it gave me the extra room i needed to twist the pipe out.
    I didn't find swearing helpful.

    Just one washer; i think it's there as reference to avoid overtightening, I've lost mine the first time i took the pipe off and i never felt the need to replace it
    #7
  8. dwj - Donnie

    dwj - Donnie Long timer

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    I was able to perform the job without removing the pipe. With it dis-connected at both ends I could work around it.
    #8
  9. Orangecicle

    Orangecicle On a "Quest"

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    "It's kinda like sex." :lol3

    <iframe width="560" height="315" src="//www.youtube.com/embed/RIOvOMgzOSs" frameborder="0" allowfullscreen></iframe>​
    #9
  10. dwj - Donnie

    dwj - Donnie Long timer

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    BTW, the shaft and seal at 28,285 miles showed no wear.
    #10
  11. GLRRA47

    GLRRA47 Adventurer

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    I ended up removing one allen - head bolt from the right side engine case and the header slipped right out. I think it was the one directly above and behind the clutch cover. Made a world od difference.
    #11
  12. seedman

    seedman Adventurer

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    Just loosen the rear clamp, remove the nuts at the cylinder head and loosen the pipe. Either then or before, remove the heat shield. Since you are removing it anyway take the water pump cover off and the pipe will come out very easily. Put it back in reverse order. Its nice to have it out of the way. And yes, only one washer up front.
    #12
  13. DirtyADV

    DirtyADV Long timer

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    This was one thing that was better on the early 950s that had a shorter heat shield that I have never removed.

    On the 990 it was not easy at all getting it out with both shield and pipe loose it was possible to wiggle shield out and then get pipe out.

    When putting together I had forgotten to place heat shield and with pipe in place there is NO way to get heat shield in place so choose to cut it:

    [​IMG]

    Carbon shield might not have been that smart since metal one seems to act as a heat sink drawing some heat from the bolts with carbon one I top out over 200 degree C (what is that in illogical fahrenheit ...like 400?) in bolt temperature and that melts pants, will have to address this winter, have new clothes on order and would just to melt them right away.

    /Johan
    #13