View Full Version : DIY- Installing Zartan's Exhaust Hanger


kkim
November 24th, 2008, 03:22 PM
First off, thank you to Starla for the great customer service and the effort she and her husband have gone through to develop a hanger just for our bikes. :drinkpals:

http://mysite.verizon.net/res7x2ni/exhausthangerninja250r/

Tools needed for install... 6mm Allen head bit, 17mm socket and wrench, six pack of thinking material. :D


Picked up the package from the post office this morning.

http://lh4.ggpht.com/kkim993/SMg6WW9mzYI/AAAAAAAAA8Q/9MkWN3ZMdAo/s640/DSC04566-1.JPG


Oh, oh... postal service at work.... doesn't look good...:mad: have a beer. :drinkingbeer:

http://lh6.ggpht.com/kkim993/SMg6XlFnVfI/AAAAAAAAA8Y/Oagn6yofJos/s640/DSC04567-1.JPG

Whew... contents inspected and all looks to have survived... have another beer to calm myself down. :drinkingbeer:
http://lh3.ggpht.com/kkim993/SMg6YesN20I/AAAAAAAAA8g/adBwjGhG-BM/s640/DSC04568-1.JPG

this is what is included in the package...
http://lh5.ggpht.com/kkim993/SMg6ZIqwCbI/AAAAAAAAA8o/fNhed2ycv6Q/s640/DSC04569-1.JPG

http://lh6.ggpht.com/kkim993/SMg6bSiYCRI/AAAAAAAAA9A/WALyNYlRBGA/s640/DSC04572-1.JPG

okay... time to get busy installing this puppy... wait, what does it weigh?? Keep in mind I bought the powder coated steel black brace. They also sell an aluminum version that weighs about half as much if you are interested in saving a few more ounces.

http://lh5.ggpht.com/kkim993/SMg6ce5jM3I/AAAAAAAAA9I/08q33E4PfHA/s640/DSC04573-1.JPG

Okay... now let's get busy w/ the install...

Bike up on stand to show the before...

http://lh5.ggpht.com/kkim993/SMg6etXqtXI/AAAAAAAAA9Y/gu7GFfQoHME/s640/DSC04575-1.JPG

Use a 6mm Allen bit to remove the 2 bolts holding the left side passenger foot peg bracket.

http://lh3.ggpht.com/kkim993/SMg6gg28reI/AAAAAAAAA9o/50_u5ZO1K6w/s640/DSC04577-1.JPG

left side removed... whew, time to have another beer... this is exhausting.:D :drinkingbeer:
http://lh5.ggpht.com/kkim993/SMg6huoOENI/AAAAAAAAA9w/68Fet6Z2bVY/s640/DSC04578-1.JPG

continued on next post... whew... and time to have another beer... :drinkingbeer::cheers::drunk1:

kkim
November 24th, 2008, 03:23 PM
Next, move over to the right side of the bike and remove the bolt that holds your muffler to the passenger bracket. Whew, all that moving deserves a beer... :smile-drink4:

http://lh6.ggpht.com/kkim993/SMg6jyzCpVI/AAAAAAAAA-A/GLgK_ljsAHw/s640/DSC04580-1.JPG

and next, remove the passenger bracket using the 6mm bit...

http://lh5.ggpht.com/kkim993/SMg6lw5dUjI/AAAAAAAAA-Q/3qhE5OGfgAs/s640/DSC04582-1.JPG

http://lh6.ggpht.com/kkim993/SMg6mhk_B0I/AAAAAAAAA-Y/KkpLoAbCxbs/s640/DSC04583-1.JPG

http://lh3.ggpht.com/kkim993/SMg6n-8LnaI/AAAAAAAAA-g/NPiv24k_og8/s640/DSC04584-1.JPG


put the hex head bolts you took off the old bracket and put it through your new hanger. I elected to put the spacer washers that's included on the back side so it ends up between the hanger and the frame when installed.

http://lh6.ggpht.com/kkim993/SMg6q-geJPI/AAAAAAAAA-0/nila9Iauxfk/s640/DSC04586-1.JPG

tighten up the hex head bolts and you should be left with this...

http://lh6.ggpht.com/kkim993/SMg6s4xWHaI/AAAAAAAAA_E/q68isFAMu5c/s640/DSC04588-1.JPG

follow the directions included with the hanger to select the hardware designed for your bike to properly install the hanger. This a pic with the included spacers and bolt in place being tightened up.

http://lh6.ggpht.com/kkim993/SMg6w6E2nVI/AAAAAAAAA_k/Ru6YhfFmIeA/s640/DSC04592-1.JPG

I tightened the bolt (17mm) while holding the nut (17mm) and tightened the assembly till the rubber spacer started looking like the Michelin man's fat fold...

http://lh6.ggpht.com/kkim993/SMg6zKRlwfI/AAAAAAAAA_0/PIgwp4o4nxQ/s640/DSC04594-1.JPG

Don't worry about the nut backing off. A nylock nut is included which precludes any chance of the nut coming loose. I'll drink to that...:smile-drink3:

After tightening the muffler up, I noticed the muffler sitting very close to the swing arm. To space it out, I pulled the muffler outward to gently bend the hanger a bit so the muffler would have enough clearance from the swing arm. Pic of the muffler after adjusting it for clearance.

http://lh4.ggpht.com/kkim993/SMg63B1zV1I/AAAAAAAABAU/r1T78heUF6w/s640/DSC04598-1.JPG


So, you're done! :)

This is the result w/ the new hanger.

http://lh4.ggpht.com/kkim993/SMg64HYvRZI/AAAAAAAABAc/7lzGYjsuD8Y/s640/DSC04599-1.JPG

http://lh4.ggpht.com/kkim993/SMg66KwHDPI/AAAAAAAABAs/ytd1_zxKKFk/s640/DSC04601-1.JPG

http://lh5.ggpht.com/kkim993/SMg68KZorDI/AAAAAAAABA8/JabkIRWeep4/s640/DSC04603-1.JPG

and a "before shot for comparison...

"http://lh4.ggpht.com/kkim993/SMg6frXRdeI/AAAAAAAAA9g/5qZN7jtBZM0/s640/DSC04576-1.JPG

Last, the stock brackets and peg weight...

http://lh3.ggpht.com/kkim993/SMg68wDvg7I/AAAAAAAABBE/Rg4TOf7XtNI/s640/DSC04604-1.JPG

Losing 2 pounds never looked so good! :drunk1:

Kudos to zartan for making this product. It's fits perfect, is well thought out and installation was a breeze with no hidden problems. I think the removal of the passenger pegs and brackets really cleans up the bike and looks great. Now to get busy and relocate that rear brake reservoir. :p

installation could be done in ten minutes if you don't stop too often to take pictures and drink too much beer. :smile-drink4:

speaking of too much beer... scuse' me... :puke:


http://mysite.verizon.net/res7x2ni/exhausthangerninja250r/

Felix
November 27th, 2008, 01:17 AM
Pure sexyness... love this bit of gear, really makes the rear of the bike look different.

http://i161.photobucket.com/albums/t233/felixXR6T/Image009-4.jpg

http://i161.photobucket.com/albums/t233/felixXR6T/Image010-3.jpg

Felix

zartan
December 9th, 2008, 01:17 AM
Hi Gang, :hellokitty:
Just an FYI. I am offering free US shipping for the Hangers til Christmas. That's 8 bucks off. But you need to order off my direct site and not the ebay one.

Ebay is tooooooo expensive. And they raised their prices a few months back for seller. yikes. Makes it hard to give discounts

so go here, tell a friend:)
Direct site is here:

http://mysite.verizon.net/res7x2ni/exhausthangerninja250r/

Cochese
December 18th, 2008, 10:24 PM
Hi Gang, :hellokitty:
Just an FYI. I am offering free US shipping for the Hangers til Christmas. That's 8 bucks off. But you need to order off my direct site and not the ebay one.

Ebay is tooooooo expensive. And they raised their prices a few months back for seller. yikes. Makes it hard to give discounts

so go here, tell a friend:)
Direct site is here:

http://mysite.verizon.net/res7x2ni/exhausthangerninja250r/

Done and done.

Can you send the hardware for stock AND a Two Bros full exhaust?

zartan
December 18th, 2008, 11:49 PM
done and done :) Should fit. I have sold to lots of folks. Mine and TR's Yoshi are fat buggers and it fits. I used an extra spacer for the nut clearance on my lowered bike just to be sure. Love a pict and feedback on the fit. cheers.
Will go out Friday tomorrow,
you should hopefully have it by Tuesday. 2-3 day priority. AND just because it is the holidays I will throw in a whole two bros. exhaust.. haha not really.:p

zartan
March 23rd, 2009, 11:36 PM
Bumping because I have 4 seconds out of my latest batch. Paint not perfect minor, I am just real picky about the powdercoating paint. I will sell for 50 SHIPPED - that is 18 dollars off the 60+ 8 shipping. so holler if you are interested in a PM and I will paypal you an invoice. Complete hardware is included.
Don't order the off of my site or ebay because it won't give you the
2'nds discount. Only 4 available at this price. pm ok

M-Oorb
March 29th, 2009, 04:19 PM
Just bought one of Zartans 2nds. Sent me a picture of the product before I bought it just to see how bad the powdercoating was and if I could live with it. All I have to say is talk about quality control...the discrepancy was barely there! So i would advise anyone who wants one to save themselves 10 bucks and the shipping and pick a Zartan exhaust hanger up today! But if you don't wanna buy a "2nd" the price is still totally worth it just by what I can tell from the quality control :thumbup:

zartan
March 29th, 2009, 08:45 PM
Thanks for the kind words :)

CaliGirl
April 6th, 2009, 07:19 PM
Any one have pics of this hanger with a stock exhaust?

B2FiNiTY
April 6th, 2009, 11:22 PM
I'm interested in a "2nd" cheaper one. let me know if available.

zartan
April 7th, 2009, 12:29 AM
PM Sent!! I have second's kits left.

Jiu Jitsu Player
April 19th, 2009, 07:02 PM
I just got my "2nd" in the mail from Zartan. From what I can tell there may be a few molecules that are off, but I didn't feel like breaking out my electron microscope to verify. To the naked human eye it looks perfect. This is an awesome product with super fast shipping. I can't wait to get it on the bike! Thanks Zartan.

zartan
April 19th, 2009, 07:49 PM
yea !!!and so glad you are HAPPY :)
One second left !!

Jiu Jitsu Player
April 21st, 2009, 02:34 PM
I installed the hangar yesterday. Everything looks great but I had a hell of a time trying to get the stock muffler lined up with the hole on the hangar to put the bolt through. I really had to apply a lot of upward pressure to get them to align and put the bolt in. Once I got it in everything seemed ok. I don't think it has anything to do with the hangar since I held it over the stock hangar and they lined up almost identically. I'm a little worried about the upward stress that is being placed on the muffler. I know the stock is aluminum but Im planning on replacing it with a CF exhaust in a few days and I dont know if I want to put that kind of upward pressure on the new exhaust for fear of it breaking. Is it normally this hard to get the holes to align? Anyone else had any experience with this?

CaliGirl
April 21st, 2009, 02:41 PM
I installed the hangar yesterday. Everything looks great but I had a hell of a time trying to get the stock muffler lined up with the hole on the hangar to put the bolt through. I really had to apply a lot of upward pressure to get them to align and put the bolt in. Once I got it in everything seemed ok. I don't think it has anything to do with the hangar since I held it over the stock hangar and they lined up almost identically. I'm a little worried about the upward stress that is being placed on the muffler. I know the stock is aluminum but Im planning on replacing it with a CF exhaust in a few days and I dont know if I want to put that kind of upward pressure on the new exhaust for fear of it breaking. Is it normally this hard to get the holes to align? Anyone else had any experience with this?


I had the same issue trying to install the hanger with my stock exhaust. I didn't want to force it, so I didn't put it on. I don't understand cause the hanger lines up perfectly with the stock bracket. I was hoping someone else would chime in about their install with a stock exhaust, but no one besides you has.

Jiu Jitsu Player
April 21st, 2009, 03:43 PM
At least I know Im not the only one. I dont think too many other people have picked this up to use with just the stocker though. I should be getting a new exhaust in the mail sometime this week. I'll let you know how that install goes. This maybe a problem that only happens with the stock pipe....

kkim
April 21st, 2009, 06:14 PM
Try loosening the clamp used to mount the muffler to the header. Adjust and see if the muffler will line up better with the hanger. position into place until you are satisfied, then retighten that clamp, then tighten the bolt for the hanger.

exhaust systems rarely line up perfectly and some adjustment to get them on perfectly may be needed.

Jiu Jitsu Player
April 21st, 2009, 06:16 PM
Thanks Kelly. As usual you come through! I'll check that out when I get home.

zartan
April 21st, 2009, 08:20 PM
Hi, Thanks for the feedback guys. You can always pm me or email me with any issues.... Sorry I did not see this sooner.


KKIM thank so much for you helping out.

I mounted them with both stock and aftermarket pipes on both my and TR's bike to test fit. And yes We did not tighten everything up until positioned. THEN the last thing is to tighten the clamp.


If this still does not work, I need to know asap thanks so much! I want feedback!!! zartan1@verizon.net

Try loosening the clamp used to mount the muffler to the header. Adjust and see if the muffler will line up better with the hanger. position into place until you are satisfied, then retighten that clamp, then tighten the bolt for the hanger.

tjbrien
May 2nd, 2009, 07:33 AM
I just finished the install with a stock exhaust. If ya loosen the muffler clamp then insert and snug up the hanger bolt then tighten both it aligns itself.

The question I have is what can I use to fill the holes for the bolts that secured the left passenger foot bracket. I put the original bolts back in but they stick out because of the shoulder on the bolt. I'm not sure which looks worse the empty holes or the bolts so I thought I would ask the creative and clever folks at Ninjette.org

zartan
May 2nd, 2009, 11:07 AM
Perfect opportunity to create some bling :) Thanks for the install feedback glad it fit well!

Sound Wave
May 2nd, 2009, 12:28 PM
I just finished the install with a stock exhaust. If ya loosen the muffler clamp then insert and snug up the hanger bolt then tighten both it aligns itself.

The question I have is what can I use to fill the holes for the bolts that secured the left passenger foot bracket. I put the original bolts back in but they stick out because of the shoulder on the bolt. I'm not sure which looks worse the empty holes or the bolts so I thought I would ask the creative and clever folks at Ninjette.org

trying to find a pic of what i mean, but they sell black plastic plugs. the side that shows looks like a disk which would be near fllush to the metal. the side that would stick into the screw hole is kind of serrated so that it doesn't slip out. that would hide the screw hole pretty good. you know what i am talking about? kind of hard to describe without a pic.

something like this, but this isn't the one i am talking about: http://www.allianceplastics.com/rdg

edit: ok, i can't find it, but i drew a pic of what i am talking about. btw, it is really hard to draw with a mouse.

tjbrien
May 2nd, 2009, 12:58 PM
Great idea Sound wave! I know exactly what ya mean, I've seen them I just can't remember where. As a short term solution I put in some button head allen screws.

zartan
May 2nd, 2009, 01:09 PM
Trying to think of something that won't look goofy. Maybe I should design a decal for that side Plate.

Or a cell phone holder haha!! or reach down and grab your cup of joe??


i just put the stock bolts back in mine and I am really OCD --after awhile I chilled on it.

But now you got me shaking again :confused30:

tjbrien
May 2nd, 2009, 01:49 PM
Sorry about the shaking, a decal's not a bad idea. If ya could get the Ninja typeface, have the letters horizontal but the word ninja ascending to the right.

Sound Wave
May 2nd, 2009, 01:51 PM
hmm... autozone has something like it. i was picturing a flatter disc, but i am sure they would work. not sure if they sell them in packs of less than 10 though. they probably have other styles too.

http://www.autozone.com/autozone/catalog/accessories/accProductDetails.jsp?displayName=Fastener&itemId=prod11860&navValue=100885&parentId=cat10043&productId=732680&fromString=search&itemIdentifier=732680_0_0_&filterByKeyWord=fastener&categoryNValue=101313&subSubPartId=&subPartId=prod11860&store=5433&skuDisplayName=10pcs.GaugePodandPillarFastener&categoryDisplayName=Fastener,ScrewandHardware&_requestid=623660

edit: actually, you could also just get a sheet of a flat black vinyl sticker. cut it and match the metal bracket exactly. place it over and then no more holes and a really clean look. :D

kkim
May 2nd, 2009, 09:19 PM
I put a sturdy tie wrap in one of the holes to act as the anchor point for the bungeee cord for my tail bag.

BlueRaven
May 2nd, 2009, 09:24 PM
kkim i'm starting to wonder if you have anything stock left on your bike....just teasing ;)

Jiu Jitsu Player
May 2nd, 2009, 10:02 PM
Just use some electrical tape. That's what I used on the fender elim holes for the turn signals after I switched to flush mounts.it may sound ghetto but its doesn't look bad and its really hard to tell unless you get up really close.
Posted via Mobile Device

tjbrien
May 3rd, 2009, 05:41 AM
I sawed off the button head allen screws so they don't stick out past the flange they're screwed into and painted them black last night. Looking better but I'm going to look into the plastic plugs this week.

Sound Wave
May 3rd, 2009, 08:14 AM
i saw the plugs at a local hardware store. i would guess that lowe's and home depot has them too. it was in the nuts and bolts section.

Bo0stZomb13
April 24th, 2011, 07:43 PM
I know its old but can you still get this hanger?

kkim
April 24th, 2011, 07:53 PM
I believe so... send a PM to zartan. :thumbup:

Cochese
April 24th, 2011, 10:38 PM
I know its old but can you still get this hanger?

I have one new in the package, $30 shipped to your door.

zartan
April 24th, 2011, 11:29 PM
Yes pM cochese.. that is a good deal for sure.
I am not sure if I am running a new batch this year.

Cochese
April 25th, 2011, 12:17 AM
Yes pM cochese.. that is a good deal for sure.
I am not sure if I am running a new batch this year.

Thanks, Starla!

In the event I can't locate the accompanying bolts and nuts in my garage, can you provide the specs for those?

I assume they are standard and readily available at ACE/HD/Lowes for a few bucks?

zartan
April 25th, 2011, 11:59 PM
I can get you specs on hardware, the rubber bushing is something I get from a suspension co. but NAPA carries something similar 2 in a package for 5 bucks. let me know if you can't find the parts.

kkim
April 26th, 2011, 12:42 AM
Starla... you're one class act!! :thumbup:

it's been over 2 years since I first installed your hanger and still use it to this day without any problems.

zartan
April 26th, 2011, 01:20 AM
Thx KKim, back at ya!

Cochese
April 26th, 2011, 01:20 AM
I can get you specs on hardware, the rubber bushing is something I get from a suspension co. but NAPA carries something similar 2 in a package for 5 bucks. let me know if you can't find the parts.

Found them!

Thanks!

zartan
April 26th, 2011, 01:33 AM
Ha.now I am wondering if I should run a new batch. I received another request. Want to make sure there is enough interest,
it is an investment to run a batch. So anyone else interested?
Kits are running around 60 bucks plus shipping if I do. I use local labor so they are spendy to produce but worth it to me. Probably 4 weeks out if I decide to do some for this year.

zartan
April 26th, 2011, 01:33 AM
Found them!

Thanks!

cool!!

Cochese
April 26th, 2011, 03:11 PM
Mine is sold folks. Thanks!

ACT250R
April 26th, 2011, 04:41 PM
Zartan, i would be keen.

Where are you located exactly? Aus or US?

zartan
April 26th, 2011, 06:43 PM
US