I bought a Yoshimura full system off of a guy on ebay. It came in today and I tried to install it but ran into some problems. Since it is used, the manifold and flanges are both still attached to the header. I undid the springs, and attempted to pull out the manifold, with no success. Those things are SO tight in there. I even tried to leverage them out against the flanges, but had no luck. What do I do? Would it help if I heated the header/manifold area up w/ a small butane torch (not holding it RIGHT ON IT, but getting it hot just the same)? Would they come out easier?

I am waiting for a buddy of mine to come over tomorrow and try to help, but in the meantime, can you offer up any suggestions?

03' Gixxer 600.
Yoshimura Full RS-3 Race Exhaust.

Thank you

Maybe a lil rubber mallet action is needed. I don't know I'm having a hard time understanding what you're having trouble with.

ill try to find a better pic on the internet i can show.....
basically its the spot below in the read. there is a widening at the top of the header so that the manifold piece can fit in. behind that manifold pieces of the flange. i cannot get the manifold pieces out of the header, they are super tight. maybe rubber malet will do it, i can try tomorrow


http://www.gixxer.com/uploads/i118.jpg

I think i might be having the same problem. I just got a RS3 full system off eBay and my shop said that the header ports are too big and it doesn't fit. Maybe that is what is happeneing to me as well. Please let me know what happens.

L - Dawg

navarrojiii@hotmail.com

do you think that they are for the 00 750 exhaust I would check the diameter and then measure the diameter of your bike since you have a 600 you maybe able to find it else where or cross refrence the numbers on yosh site see if they have same number

damn where the hell do you guys find these pipes on ebay
i want one

Ok.
Its all installed and AWESOME.
The problem was that I was a pussy. I was afraid of hurting the pipe, but using a rubber mallet and the lifesaving LIQUID WRENCH, the pieces came apart easily. It is all hooked up and looks great! $620 for this full system delivered to my door. Now tomorrow I program my PCIII.

gotta take some pix soon

Can you explain your whole process, why you took off the manifold pieces? Shouldn't they fit right on your motor without any modifications? What did you do after you took them off? Don't you need the piece you were trying to hammer out so you can screw it to the engine? Please give an explanation. Thanks

L-Dawg

Yeah, got to be a little rough with it. http://www.gixxer.com/forums/images/graemlins/smile.gif

I installed one two nights ago, full system, high mount... price 275 has a little damage, but can you see any??

I also have a PC3 USB coming Friday. http://www.gixxer.com/forums/images/graemlins/smile.gif

http://webpages.charter.net/lind/images/03gsxr.jpg

ljordan said:

Can you explain your whole process, why you took off the manifold pieces? Shouldn't they fit right on your motor without any modifications? What did you do after you took them off? Don't you need the piece you were trying to hammer out so you can screw it to the engine? Please give an explanation. Thanks

L-Dawg



Not sure what other people call them, but I have heard them as collars? Anyway the pieces he had circles fit up into the existing exhaust ports. You have to take out the stock gaskets that are on there, but on my install it was easier to pop off the "collars" and put those into the bike first, then I slid the exhaust headers into them and put the springs on and whalla. All done. http://www.gixxer.com/forums/images/graemlins/thumb.gif

The way that Yoshimura recommends you do it is you place the manifold collar piece into the head and secure it down w/ the 2 bolts and the flange. Once this is complete, you simply put each pipe from the header into the manifold "collar" piece , then tap them in with a rubber mallet. After this is done, you secure them w/ the springs.

My problem was just that those manifold collars and flanges came already in the header pipe and were SO damn tight, but it appeared that nothing a little bit of liquid wrench and a rubber mallet were unable to conquer.

I just did my PCIII today w/ a map i got off the net, hopefully that should help too.
Mine has not a single scratch or dent in the entire system and i paid $570, so it isnt a bad deal. Yours you got real cheap it seems, but you said ti has damage, but no, I cannot see any.

TWISM said:

Yeah, got to be a little rough with it. http://www.gixxer.com/forums/images/graemlins/smile.gif

I installed one two nights ago, full system, high mount... price 275 has a little damage, but can you see any??

I also have a PC3 USB coming Friday. http://www.gixxer.com/forums/images/graemlins/smile.gif





only 275??? i priced one out at like 1300 for a full ti. where do i get one!!

-jay

Maybe in Titantium ya. I have stainless, he prob does too.

I just sold one on ebay for 300. Try there.

Does anybody know the weight difference between the stainless headers and the Ti headers? I have been looking for a deal on them but it doesnt seem that anybody has the Ti headers for a 750.

To MrJones44:

If I remember right and I think I do,when I was looking for a Yosh for my 750 the weight diff was only 2 pounds for only twice the price. I got the SS.

my 1k came stock with suzukis ti system i replaced it with a stainless yosh rs3 the yosh was considerably heavier the can is longer too much better qaulity though and the sound is mean compared to stock

email "ranson910@aol.com" hes got a full akro and a PC3 that hes SELLING CHEAP! Might be on ebay by now though. I didnt have the money and still dont or id have it.
-Alex

spdfreq said:

my 1k came stock with suzukis ti system i replaced it with a stainless yosh rs3 the yosh was considerably heavier the can is longer too much better qaulity though and the sound is mean compared to stock



You still save weight compared to stock since you lose the SET valve....