How to remove stock header pipe???? - Suzuki Z400 Forum : Z400 Forums
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post #1 of 18 (permalink) Old 03-28-2011, 05:25 PM Thread Starter
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How to remove stock header pipe????

I have a 2003 LTZ 400 and i was trying to change the exhaust out on it. I removed the muffler and then disconnected the two bolts for the header pipe so its free now i just cant seem to figure out how to get it out. I was wondering if there was a trick or side that you take it out from etc? I know im sure you all think "what a noob" but this is starting to make me mad lol

Thanks all
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post #2 of 18 (permalink) Old 03-28-2011, 05:28 PM
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Think you get to loosen up the radiator if thats what your talkin about

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post #3 of 18 (permalink) Old 03-28-2011, 05:56 PM
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I took the thermostat out to get it out. very easy once thats out of the way

03 z400
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Alba Pro-Peg Nerf Bars
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post #4 of 18 (permalink) Old 03-28-2011, 07:29 PM
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t-stat or radiator needs to go. aftermarket headers are so much easier! (if thats what you are switching to?)
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post #5 of 18 (permalink) Old 03-28-2011, 08:59 PM
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bust out the sawzall!

2003 ltz400
fmf powerbomb, pro circuit t-4
K&N
jetted...160 mikuni main 22.5 pj, stock needle 2.5-3 turns
full skid plates
blingstar bumpers
pro taper 7/8's
barkbusters parking break MIA
razr 2 rears 20x11-9 holeshot gncc fronts 21x7-10 3" spacers f&r
13t front sprocket
5000k HIDs
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post #6 of 18 (permalink) Old 03-28-2011, 09:10 PM
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you know it ,its not like its ever going back on

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03 ltz400,95.5bore,+5crank,P&P,13.7:1,JE piston,spacer plate,RHC +1 intakes valves,RHC #208in&187ex cams,DRZ manual decomp,DID cam chain,no air box,Sredrum TB 42mm FCR,RAT stack,WB fuel screw,EMN needle,quick shot,06 clutch 450r drive plates w/trx400 ex springs,C2HB,ex thumber,trx450r air boot, Barker Performance pipe, trailteck flywheel,dynatek,NOLOGY HOTWIRES ,nerf bars,450r shocks, nerf bars,+4 swinger,lowered front & rear
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post #7 of 18 (permalink) Old 03-28-2011, 09:16 PM
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There is a great thread on here with a step by step how to do this, but basically you remove the radiator bolts, clamp the radiator hose so you don't spill a bunch of antifreeze and disconnect the hose from the engine.once you have done that it will slip out pretty easily.

07 Suzuki LT Z400 (Future QOTM )
04 Kawasaki KFX 400 (Dec. 2012 QOTM)
07 Can Am DS 250 (Oldest Son's)
07 Yamaha Raptor 50 (Youngest son)
07 Yamaha TT R50 (A Fun Little Toy)

Need to install:
DRZe Kit
RatStack
FCI Intake
Ferrea Valves
Athena 434 BBK
Dynatech NP CDI
IMS 4g Fuel Tank
Titanium Wrist Pin
Raptor 660 Petcock
YFZ Thumb Throttle
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K&N Crank Case Filter
Web Cams 539/539+3
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post #8 of 18 (permalink) Old 03-28-2011, 09:18 PM
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Read this, it'll be way easy if you do.
The Solution To Headpipe Removal! (pictures!)

07 Suzuki LT Z400 (Future QOTM )
04 Kawasaki KFX 400 (Dec. 2012 QOTM)
07 Can Am DS 250 (Oldest Son's)
07 Yamaha Raptor 50 (Youngest son)
07 Yamaha TT R50 (A Fun Little Toy)

Need to install:
DRZe Kit
RatStack
FCI Intake
Ferrea Valves
Athena 434 BBK
Dynatech NP CDI
IMS 4g Fuel Tank
Titanium Wrist Pin
Raptor 660 Petcock
YFZ Thumb Throttle
DID 520 ERT2 Chain
K&N Crank Case Filter
Web Cams 539/539+3
CP 94mm 12.5:1 Piston
FCR-39 from 450 Outlaw
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post #9 of 18 (permalink) Old 03-28-2011, 09:53 PM Thread Starter
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If i were to just cut it in half that would solve that prob When it comes to putting in the aftermarket ones should it go right in without problems? I havent even looked at it yet to see how diffrent they are.
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post #10 of 18 (permalink) Old 03-28-2011, 10:02 PM
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sawzall. It's never going back on and they have $0 resale. Make it easy on yourself. THe aftermarket will slip right in.

BUICK BROTHER

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post #11 of 18 (permalink) Old 03-28-2011, 10:02 PM
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yea just cut the stock one somewhere in the bend and itll pop right out and the new one goes in smooth as glass dont have to move anything. what did you get?

2003 ltz400
fmf powerbomb, pro circuit t-4
K&N
jetted...160 mikuni main 22.5 pj, stock needle 2.5-3 turns
full skid plates
blingstar bumpers
pro taper 7/8's
barkbusters parking break MIA
razr 2 rears 20x11-9 holeshot gncc fronts 21x7-10 3" spacers f&r
13t front sprocket
5000k HIDs
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post #12 of 18 (permalink) Old 03-28-2011, 10:15 PM Thread Starter
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Then thats what ill do I went with the pro circuit t-4 with head pipe....Im new to all this so i hope its an ok choice.
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post #13 of 18 (permalink) Old 03-28-2011, 10:25 PM
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sounds good man....thats what i have only with a powerbomb header...you will love it. i think its a great soundin pipe. not annoying loud but has plently off bark to it

2003 ltz400
fmf powerbomb, pro circuit t-4
K&N
jetted...160 mikuni main 22.5 pj, stock needle 2.5-3 turns
full skid plates
blingstar bumpers
pro taper 7/8's
barkbusters parking break MIA
razr 2 rears 20x11-9 holeshot gncc fronts 21x7-10 3" spacers f&r
13t front sprocket
5000k HIDs
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post #14 of 18 (permalink) Old 03-28-2011, 11:14 PM
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With th pc you have to remove radiator to put it in its a real pain!!

03 Athena bbk,k.w.springs,port&polish,dyna prog, web540-540, Procircuit fullsystem ,39mmfcr, custom airbox intake built by me w/400ex tube and +4hotrods, Rekluse clutch, Elka LT shocks, burgaurd+2 a-arms, Protaper bars, ASV levers, ODI grips, AC propeg nerfs, ATV foreplay? +1 1/4swinger, Maxxis razor2S, black hyper wheels, Houser plus 1 stem, HID conversion, modded yamaha parking brake, G-force axle, and a woodsrider129 rotorgaurd and quick change clutch cover!
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post #15 of 18 (permalink) Old 03-29-2011, 12:45 AM
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if you read the thread I posted above it makes the stock removal easy and you don't have to cut it.

07 Suzuki LT Z400 (Future QOTM )
04 Kawasaki KFX 400 (Dec. 2012 QOTM)
07 Can Am DS 250 (Oldest Son's)
07 Yamaha Raptor 50 (Youngest son)
07 Yamaha TT R50 (A Fun Little Toy)

Need to install:
DRZe Kit
RatStack
FCI Intake
Ferrea Valves
Athena 434 BBK
Dynatech NP CDI
IMS 4g Fuel Tank
Titanium Wrist Pin
Raptor 660 Petcock
YFZ Thumb Throttle
DID 520 ERT2 Chain
K&N Crank Case Filter
Web Cams 539/539+3
CP 94mm 12.5:1 Piston
FCR-39 from 450 Outlaw
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