Update: Definitive KZ650 installation of Delkevic 4-1 exhaust. I did it!!!!

Street Fighter LTD wrote: Have a extra set of hands helping you.
Getting it off can require some contorting to get pipes off as a assembly .
Also make sure the bike is held steady or it may end up falling on top of you.
Dave

Even on the center stand? I really want to do this solo. I was hoping I didnt need an extra set of hands!

On the center stand it'll be stable.
If your on your own you will be better off removing one side at a time. You'll need to loosen the cross over balance pipe underneath if you still have one so the you can remove each side seperately. Leave the two headers and muffler connected together and remove the side where you loosened the cross over first. Then the other side.

Warren3200gt wrote: On the center stand it'll be stable.
If your on your own you will be better off removing one side at a time. You'll need to loosen the cross over balance pipe underneath if you still have one so the you can remove each side seperately. Leave the two headers and muffler connected together and remove the side where you loosened the cross over first. Then the other side.

Might have a shop just around the corner from me do it. Im short on time this week and they are not going to charge me a lot it seems. I'll decide later on this week.

All in All? I hope you have cleaned up the rusty studs. Maybe have wire brushed off all the rust and scale you could.
And have been soaking the studs with some spray penetrant for the past 2 weeks since this picture.
Just do it! The suspense is killing me!! :woohoo: :woohoo:

z1kzonly wrote: All in All? I hope you have cleaned up the rusty studs. Maybe have wire brushed off all the rust and scale you could.
And have been soaking the studs with some spray penetrant for the past 2 weeks since this picture.
Just do it! The suspense is killing me!! :woohoo: :woohoo:

I'll take a pic of the studs before the new one goes on. The penetrant, which I have sprayed on it almost every day before riding the bike (only to watch it smoke off once the bike is up to operating temperature - but hopefully penetrant is seeping in) has REALLY cleaned up the studs and bolts. Looks like a whole different ballgame.

Street Fighter LTD wrote: Have a extra set of hands helping you.
Getting it off can require some contorting to get pipes off as a assembly .
Also make sure the bike is held steady or it may end up falling on top of you.
Dave

Came in the mail today. Here we gooooooo!

650Dude wrote:

Street Fighter LTD wrote: Have a extra set of hands helping you.
Getting it off can require some contorting to get pipes off as a assembly .
Also make sure the bike is held steady or it may end up falling on top of you.
Dave

Came in the mail today. Here we gooooooo!

Definitely putting this on myself. Mechanic said he could do it for $285. No way am I paying that. Fingers crossed it all turns out OK. I plan on doing it EARLY Sunday morning before church. I'll get up at 7am. Hopefully it wont take me more than an hour?

How long do you guys think it should take, barring any problems?

The old exhaust gaskets need to come out ( I use a flat blade screwdriver) and the seats need to be cleaned .
then apply a little silicone on the new gaskets and stick it them in place
You need 4 of these if they aren't included with the pipes www.z1enterprises.com/copper-exhaust-gas...-750-1300-zx750.html
I use masking tape to hold the collars in place ( the tape burns off and can't be seen)
Install all the nuts and bolts loosely at first on everything and give it a wiggle to make sure the pipes are seated correctly.
then tighten the holders half way and give it another wiggle.
If everything feels and looks like it is seated correctly tighten the holder nuts some more
Then tighten up everything else and fire her up.
Listen for a clicking noise up by the holders, that would mean you have a exhaust leak
If you hear clicking, carefully tighten up that pipe a little more, if it doesn't stop you may have an improperly seated pipe
Try that and let us know how it goes,
good luck

bluej58 wrote: The old exhaust gaskets need to come out ( I use a flat blade screwdriver) and the seats need to be cleaned .
then apply a little silicone on the new gaskets and stick it them in place
You need 4 of these if they aren't included with the pipes www.z1enterprises.com/copper-exhaust-gas...-750-1300-zx750.html
I use masking tape to hold the collars in place ( the tape burns off and can't be seen)
Install all the nuts and bolts loosely at first on everything and give it a wiggle to make sure the pipes are seated correctly.
then tighten the holders half way and give it another wiggle.
If everything feels and looks like it is seated correctly tighten the holder nuts some more
Then tighten up everything else and fire her up.
Listen for a clicking noise up by the holders, that would mean you have a exhaust leak
If you hear a click, carefully tighten up that pipe a little more, if it doesn't stop you may have an improper seated pipe
Try that and let us know how it goes,
good luck

This is super super helpful.

The copper gaskets/crush washers, were included.

Again., much appreciated

Some good news. I assembled the Delkevic exhaust last night (premature I know) just to get a feel for what it will be like on the bike.

I cant work on the bike today
but
remember those rusted nuts and bolts in the FIRST photo below? They came RIGHT off, almost without any effort. That WD-40 PENETRANT (not regular wd-40) worked like a charm!!

When I took the two most egregious looking nuts off the exhaust, the collar slid right down. So Im hoping swapping out the exhaust tomorrow will be a breeze:

I may be wrong but it looks to me that the collars are built into the new pipes so you won't need to use the old ones.
I would suggest that you put them in a baggie and keep them with the original pipes.

bluej58 wrote: I may be wrong but it looks to me that the collars are built into the new pipes so you won't need to use the old ones.
I would suggest that you put them in a baggie and keep them with the original pipes.

Yeah the new exhaust has beautiful collars. Im not going to put the old ones on the new exhaust, no way. Not even aesthetically compatible. The OEM collars will be put in a baggie.

BTW neat trick, one of the DRIEST things on the planet is a powder called Diatomaceous Earth. I put a little of that on whatever metal I store and it takes ALL the moisture out and absorbs any that may get in. Amazing stuff.