Finally got off the River and took some pics of the 800 after the header installation.
A few suggestions and observations if any of you plan on doing this. First off, these pipes are as advertised! If you know anything about Muzzy’s pipes, you know they have been making pipes for bikes for a long time. In my modest opinion, they are the nicest high quality pipes on the market. Not cheap at around $600, but the old saying about “You get what you pay for” is what these are all about. They are all stainless steel and built for the long haul. The quality with which these are bult was in evidence when I put the system together. When I pulled them out of the box, I thought no way in he!! they were going to fit under the molding and frame! But Muzzy’s did their homework on these. Everything fit with absolute unbelievable precision. It helps to have air tools! I used long 3/8″ drive socket extensions to remove the Allen head screws that held the old manifold on. A spring tool is a cheap but invaluable investment to make this a smooth removal and installation. Taking the right side panels off, and the foot rest is crucial to removing the old pipe and installing the new one. I also removed the battery and battery box to aid in installing the crossover pipe. A small amount of heat tape (Supplied) added to the side panels and battery box was all that was needed. As you can see, the header pipes are large and of equal lengths to ensure proper back pressure. They combine into one fat pipe going along the right side and split back into two, and slide under the battery box. On my 2007, the mounting bolt holes were still present on the left side from the previous year when they came with dual exhaust. 2007 was the only year they had single exhaust. 
They have since gone back to duals. It just seemed that this machine needed to breath a little more. And with the power gain I got, I would say it was worth every penny! I have a K&N air filter on order to allow it to breathe better from both ends. 
When I got it put back together and turned the key, my first thought was Oh-Oh!! No way is this thing going to be legal!!! 
But after taking it out for a thorough test beating, the packing in the pipes settled in, and I now have a nice deep rumble at idle and a sweet sound going through the RPM’s. Not intolerable at all! 
I don’t think I will have any issues with riding with guys who are unpiped. It sounds really nice. I have the “Quiet Cores” installed with the spark arrestors so that it is leagal on State trails. 
I have used and seen many pipes for snowmobiles and bikes in my days. These are far and away better than any I have seen. These are true headers, and not just tail pipe “Slide ons.” With slide ons you get sound…but still have the lame 2 into one manifold pipe and constricted air flow. If any of you plan on doing this, let me know. I would love to lend advice and maybe lend a hand if possile.
I looked all around the web and could not really find a lot of installation tips on installing dual exhaust for ATV’s, so I hope this helps anyone in looking at doing it. If you guys are on other ATV message boards, feel free to send them over here to IDO to check out the pics and add their $.02! 
