Ducati Monster Forum

BoomTubes are finally on their way here for my 05 620. I'm very excited. I plan on mounting them myself. Any tips on the process would be very helpful.

Thanks!

Nothing very specific, it is a very easy process. I'm pretty much all thumbs but managed to do it in an hour or so.
Do not forget to put back the gaskets, and make sure nothing leaks. It will be a piece of cake.

What he said.

I'd be surprised, and kind of impressed, if you managed to screw it up.

Post pictures if you do.

Hell, post pictures even if you get it right.  [thumbsup]

You'll probably need a few pints of assembly fluid

 [drink] [drink] [drink]

Ear plugs

 [clap] [clap] [clap]

...but yeah.

Necessary. Even around town.

I've been running with no exhaust since March as I sold my Remus to help fund the Boom Tubes. So I'm pretty used to loud. They are supposed to arrive today so I'll post a pic once they're mounted. Cant wait!

I'd say so, hearing loss is progressive so you don't notice it that much when the damage is being done. I went with the utter for a while before I got my Booms and wasn't too terrible decibal wise but in hindsight I should have worn ear plugs. With the Booms running around town and what not I absolutely must. I like my hearing jamming to tunes and everything else associated with hearing. When I don't wear ear plugs my left ear drum hurts more than the right (diving incident/loss of hearing) and my ears get hot and thats enough for me to plug it up.   

For me "all the gear all the time includes ear protection" I always wear ear plugs (cuz I'm married ) ;D

Should I assemble the whole thing and then mount it or should I mount the two end points that attach to the engine and then attach the pipes in the middle?

Assemble by section would be better IMO.  avoid scratching stuff when you have very little room to work with.

I do not think you can attach the vertical header in the assembled state. Do it disassembled.

Yeah I got a detailed response on this from Mark that I should probably post here for future searches on this topic. The real PITA is the rear header inside nut. Very little room to work it due to the header, engine, trellis frame and mono shock . Mark recommended a flex joint socket wrench with and extension. On my way to the autoparts store to get one.

Here it is from THE MAN himself Mark Savory...

How to install Boom Tubes:

Remove factory exhaust.  Check to make sure the 10mm jet nuts (used to hold exhaust to engine studs) are good and the gaskets within the exhaust port are still there. (sometimes Ducati installed without)
 
Mount the rear header first.  Use above  10mm jet nuts.  I like to use a 10mm deep socket (1/4 drive) with a flex joint and 6in+ long extension -- makes it easy. (to remove as well!)   Lightly snug but not tight.
 
Collector slips onto rear header.  Use spring to hold in place.
 
Front header.  Clip into collector assembly and then slide the front into the exhaust port.  Install 10mm jet nuts from before.  Install spring.
 
I then check all clearances as the system can be moved left/right a small bit.
 
Tighten 10mm jet nuts.
 
Fire and idle -- check for exhaust leaks. (shouldn't be any but check on the exhaust port to head connection -- you will feel the hot air if there is one)
 
Put 3-4 mild heat cycles into the exhaust as the ceramic coating isn't 100% cured.  After that you can dyno, full hard throttle run, etc
 
Other:
 
1) I use aluminum hot water / head duct tape on the engine for disassembly / assembly to avoid scratching things.
 
2) leave the white foam cover on the exhaust until completely installed.  The ceramic coating can be scratched and this will help protect. (ditto for tips)
 
3) All slip joints fit perfectly when here.  Sometimes with ceramic coating the thickness makes the slip joint very tight for installation.  Two tricks:  just dab with water to act as a lubricant.  If not, then get sandpaper and sand the inside of the outer slip joint.  The material is 304 stainless and won't rust either way.
 
I use ceramic coating for: 1) it makes the system visually disappear; 2) you can touch the exhaust way earlier than if uncoated -- thus why internal/external coated.  So less chance of exhaust burns over the years which are no fun.
 

Where are the pics man!!!!!!!!!!!!!  ;D

Need to pick up new exhaust port gaskets before mounting these. The old one's are spent.

Torque Settings for the flange nuts that secure the downpipe headers to the crankcase? 25nm ?? In the link below under Exhaust I believe its the one they're referring to as "special screw securing exhaust manifold to crank case" but the description has me unsure. Can anyone confirm this?

http://s658.photobucket.com/albums/uu301/technoracer/ducati%20monster%20620%20torque%20specs/?action=view&current=monstitorquespecspg1-1.jpg# (http://s658.photobucket.com/albums/uu301/technoracer/ducati%20monster%20620%20torque%20specs/?action=view&current=monstitorquespecspg1-1.jpg#)!oZZ3QQcurrentZZhttp%3A%2F%2Fs658.photobucket.com%2Falbums%2Fuu301%2Ftechnoracer%2Fducati%2520monster%2520620%2520torque%2520specs%2F%3Faction%3Dview%26current%3Dmonsteritorquespecspg3.jpg

Well they're on and it was pretty easy. They sound amazing, better than what I had hoped for and they look like Sex On Wheels  [thumbsup]


(http://farm9.staticflickr.com/8146/7634244712_e3f1a3245e.jpg) (http://www.flickr.com/photos/65036619@N04/7634244712/)
IMG_5683 (http://www.flickr.com/photos/65036619@N04/7634244712/#) by ricknieto (http://www.flickr.com/people/65036619@N04/), on Flickr