Originally Posted by DMilan
Buying a used Staintune for my '04 GT.
I bought used, too, for the same bike - no printed instructions, but here's a few tips.
If it's going to be shipped, instruct the seller NOT to pack it with loose styrofoam peanuts against the metal. Causes some kind of weird chemical action that leaves a residue on the metal that's resistant to every known (to me) solvent.
Removal of the OEM system is pretty straigtforward. You only have to remove the belly pan and the little exhaust shield, not the side fairings. A few of the header studs may back out of the head when you remove the header. No big deal, just use a couple jam nuts on the stud to reinstall.
When the header comes off, some of the exhaust port washers may fall out and some may stay in the exhaust port. Just make sure you've got 'em all reinstalled in the correct orientation when you put the ST header on.
Hanging the rest of the ST system is obvious. Don't touch the tip of the O2 sensor or use any kind of sealant or antiseize near it.
I'm sure any deficiencies in the foregoing will be revealed by our brethren! You're gonna like the sound....