Akrapovic Exhaust System Install on a '98 ZX9R

My bike had a Muzzy's full Ti exhaust system when I purchased it...not too shabby but has a big drawback that greatly affected performance. Ivan instructed me that the ZX9 needs a 4->1 collector to be completely happy in it's midrange. The Muzzy has other flaws that affected performance but the collector was the biggest one. Ivan referred me to the Akrapovic with a 4->1 collector for the best performance with his jet kit. The funny thing is that Ivan actually recommends either a stock header or Akrapovic...so it's not like he's biased at all. Let's get to the good part...

PARTS NEEDED: New header gaskets recommended...but not required. Service manual recommended for backup informational purposes.

The first thing you'll notice is that the build quality is very high. Compared to the Muzzy's system there is no comparison...here's a shot of the header mount.

1) The first mistake I made was assemble it all off the bike...not needed. This pipe was made to be installed easily..and it is easy once you've done some prep work. First remove the radiator which means drain the coolant and then start disconnecting all of the hoses and fan therm sensor plug. Once the radiator is off the rest is cake. Remove the old header, I used some WD40 to free up the header bolt nuts to prevent any complications. Unbolt the old muffler and pull the old header and pipe off. It's recommended to use new header gaskets, mine were in good shape so I cleaned them up and put them on the new header. With the new header assembled as below (missing the cylinder # 1 pipe) go ahead and put it on the header bolts coming off the block. Just put the bolts on to keep the header attached to the block, then go get your # 1 cylinder pipe and while putting it into the collector guide it onto the header bolts for cylinder #1. Make sure the #1 cylinder pipe is fully seated in the collector and go ahead and put the nuts on the header bolts.

2) Now I said just barely put the nuts onto the header bolts so you can get the header springs on ;) There should be enough room to go ahead and put 1 spring per header pipe into the hole in the clamp. In the first picture on this page you can see the hole on the clamp that the spring goes into. Don't put the other end of the spring on yet !!!! Wait until it's bolted on and then you can put the springs on the lower hooks. With a socket or other wrench go ahead and tighten up the header nuts. NOT TOO TIGHT !!!! They only need to be a bit more than hand tight... Now go ahead and put the springs on, I used channel locks (pliers that lock) to prevent slipping and taking something else out (I put a hole in my radiator first time around).

3) All you have to do now is put your extension pipe on, put the pipe on, bolt the pipe onto the bike (with the strap included with the system), and then put the rest of the springs on. To make sure you have the extension pipe on right it should stick out a hair thereby pointing the the pipe end inwards towards the seat. That's it...have fun.