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dwj - Donnie 08-31-2013 06:19 AM

How Do You Get The Front Header Pipe Off
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!

Hootowl 08-31-2013 07:00 AM

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.

rossguzzi 08-31-2013 07:18 AM

Its an intelligents test :lol3

folknride 08-31-2013 07:32 AM


Originally Posted by rossguzzi (Post 22223720)



folknride 08-31-2013 07:40 AM

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!

nomad guy 08-31-2013 09:15 AM

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.

dmn0507 08-31-2013 12:09 PM

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.


Originally Posted by dwj - Donnie (Post 22223460)
The markings on the plate make it clear that there was only one washer. Thanks!

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

dwj - Donnie 08-31-2013 06:39 PM

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

Orangecicle 08-31-2013 07:20 PM

"It's kinda like sex." :lol3

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dwj - Donnie 09-01-2013 09:11 AM

BTW, the shaft and seal at 28,285 miles showed no wear.

GLRRA47 09-01-2013 01:38 PM

Pull a bolt
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.

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