Header Swap Question - Wrist Twisters
 
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post #1 of 4 Old 01-02-2018, 02:25 AM Thread Starter
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Header Swap Question

Due to the downtime caused by my recent crash, I'm thinking I should take the opportunity to swap out the original header for a ceramic coated one I had done a couple years ago. Do I recall correctly that the radiator has to be either dismounted and moved or removed from the bike entirely to change the header?

Also, any tips for doing the job?

1986 Honda Nighthawk 700S
2002 Honda 919
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post #2 of 4 Old 01-02-2018, 05:01 AM
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Sorry to hear about your crash. Hope you are OK.

It would certainly make it easier to remove the radiator, but not necessary. I think when I did the 900RR swap, I just removed the mounting bolts so I could push it a bit forward.

Good luck and heal up quick.

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post #3 of 4 Old 01-02-2018, 08:48 AM
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Its alot easier to remove the radiator- its two #8 bolts, unplug the fan, and two hoses. It makes the header removal so much easier and allows you to gain proper access to the manifold nuts to get proper torque. Can take the opportunity to do a coolant flush (be sure to use Honda -non silicate- coolant) I just did header removals on two 919's this last week. Also be sure to replace the copper crush gaskets where the header meets the block, its cheap and provides insurance against leaks.

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post #4 of 4 Old 01-02-2018, 05:24 PM
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Quote:
Originally Posted by Nealio919 View Post
Its alot easier to remove the radiator- its two #8 bolts, unplug the fan, and two hoses. It makes the header removal so much easier and allows you to gain proper access to the manifold nuts to get proper torque. Can take the opportunity to do a coolant flush (be sure to use Honda -non silicate- coolant) I just did header removals on two 919's this last week. Also be sure to replace the copper crush gaskets where the header meets the block, its cheap and provides insurance against leaks.
IF you don't want to crack the cooling system open, do per the above except:
-remove the fan
-don't remove the hoses
This way also provides more than adequate room for everything noted above.
(It's been so long since I did mine this way, I can't remember if I used a bungee chord to hold the rad in the position I wanted it in.)
Be careful not to damage the backside of the rad fins, and a good preventive measure is a piece of cardboard cut to size and taped in place while doing the work.

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