2008 TE510 exhaust upgrade

So after 12 years of riding my 2008 TE510, I decided to really give some love to the old girl. Started out with replacing both front and rear with heavier springs and some SKF fork seals up front. Then replaced the plastics(minus tank shrouds) and put some white side panels on(kind of weird after black for all these years). The ufo kit said it fit 08’s but I did t even think about the tank change in 2010 or 2011, so tank shrouds wouldn’t fit. I’m actually ok with that because I do like my Husqvarna stickers that are from a 2007 TE610 and they are no longer available. I then ordered a JD jetting power surge tuner and some lower pegs from Mike at Motorsportz. And now to the post title..... I ordered a FMF powercore 4 for a 2009 TC450. Years ago I met a guy who had one on his 08’ TE450 and I’ve wanted to do the same since there are no exhausts available anymore for the forgotten 2008 models. Last year I bought a 2009 mid pipe and header tubes from a member here in the classifieds. Now this is by no means a plug and play install. When I received the new pipe, I found that the exhaust was the exact same size as the end of the mid pipe and would not slip inside. Obviously the TC mid pipe is completely different since that is a carbed model and there isn’t a bung for the lambda probe, but the pipe diameter is different to. So off to the local machine shop to have a talk about some modifications. They cut the end of the FMF’s pipe off and took a notch out of it and welded it so it would slip into the mid pipe. Fortunately the owner rides to so he was all for getting this project exhaust to work. So now back to trying to install the pipe and I find that the mounting holes are both off by almost 20mm. I decided to cut 20mm’s off of the extra header pipes I have so if and when I want to put my arrow exhaust back on, all I need to do is put my stock header pipes back on. Next problem is that the exhaust springs are to long to install so I made an executive decision to use safety wire in place of the springs. The next problem is that the hook on the FMF for the spring is way to far back versus the Arrow pipe so I used some safety wire to connect the spring. I didn’t really like the long piece of safety wire right there. Next step is to play with the tuner out in the backyard to get it dialed in. This exhaust project was kind of a pain, but there is a possibility for those out there that need a pipe for their 08’s since Arrow, Leo Vince, and Vance and Heins decided to stop making anything for our bastard bikes.

Continued.....