home Zard exhaust installation.
Zard full system on a 2006 S2R 800 Monster
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Ok, final slide here. Just showing the last section I put on. I found it easier to take off the short stock manifold pipe first and fit that into the Zard pipe first, then fit the left end into the mid pipe, and lastly the right side into the head, followed by tightening up the two nuts on the flange bolts (just bought the service manual on CD, it says 23 Nm torque).

It also mentions that you should use new exhaust seals and sealing paste. Later I'll post pics of the seals to buy at your dealer. I used a high temp sealant, and let it set overnight. Seems to work ok. Didn't find any leaks upon firing it up the next day.

Once this is all put together, I checked the overall alignment on everything again, checked all the bolts, etc., and put the springs on. No pics of this yet, but it's obvious where the springs go on the welded on v/u spape bits. Three spots. I find it works best to hook one side of the spring on, and take a shoe lace or twine and pull the other end down, then the string slides out. That's about it. I'll correct this doc as needed. Hope it helps. Cheers.

barnold.com