Header won't fit [Archive] - Suzuki GSX-R Motorcycle Forums Gixxer.com

: Header won't fit


jakegsxr11
04-15-2009, 06:47 PM
Well, I removed my oil pan to mock up the 1052 Yosh header on my 92 1127. It will not fit. The primaries come out too far and will not clear the oil cooler. :cursing:wtf Now I don't know what I am going to do. The seller has not been online since I PM'd him so....maybe he still has the correct one for me?

What do you guys think I should do? I'm thinking I might try to hollow out my stock pipes and use the stock header. They sound like maraccas when I shake them and rust chuncks fall out if I hit it against the ground. Has anyone hollowed out their stock pipes, can I just ram a rod through them?

jakegsxr11
04-15-2009, 06:55 PM
You can see the bottom mounting tab is at least an inch away from the mounting slot.:crying

http://i699.photobucket.com/albums/vv355/ashleyls4825/100_1141.jpg
http://i699.photobucket.com/albums/vv355/ashleyls4825/100_1142.jpg

long_av8r
04-15-2009, 06:56 PM
So with the oil cooler off the pipe still won't clear? I don't know how that's possible because I have a Yosh 1052 system on my 1127 in the photo below. I need photos of your problem to help you out.

http://i125.photobucket.com/albums/p72/notasucka3/7%20Eleven/P1130365.jpg

http://i125.photobucket.com/albums/p72/notasucka3/7%20Eleven/P1130364.jpg

http://i125.photobucket.com/albums/p72/notasucka3/7%20Eleven/P1130370.jpg

http://i125.photobucket.com/albums/p72/notasucka3/7%20Eleven/P1130369.jpg

http://i125.photobucket.com/albums/p72/notasucka3/7%20Eleven/P1130367.jpg

gotgixers
04-15-2009, 06:58 PM
I wish i lived closer Jake. Id just bring over a bunch of headers and swap you for one that fit. But that could get costly through the mail.....

long_av8r
04-15-2009, 06:58 PM
Damn, you were posting pics while I was posting mine. I see your problem now though and it's apparently unique to the 2nd gen frame. I would just space the cooller out on top and bottom to make room for the header. As you can see I am running a curved cooler on mine and had to reloate the brackets also, but that was because the cooler itself is different from the 87 750 cooler.

jakegsxr11
04-15-2009, 07:01 PM
Long....I see yours had the same problem. What did you do to secure your oil cooler?

Can you get me a close up of how you spaced out the bottom of the cooler and secured it?

long_av8r
04-15-2009, 07:04 PM
I just used a few scraps of aluminum and cut a "U" just like it is on the existing frame bracket, put a hole in the other end and then bolted it up to the existing bracket. You'll probably have to space out the top a little bit too though. Make sure you turn the bars lock to lock to check clearence when you do.

wolfzero
04-15-2009, 07:16 PM
you posted pics while was typing too :lol
2nd gen are tighter radius on the headers, as long says your gonna have to check clearances and make something to fit

jakegsxr11
04-15-2009, 07:24 PM
I can machine a spacer for the top real easy on a lathe. I'm going to go check and see if there is a bracket I can bolt a new bottom mount to. There isn't much room to space it out until I hit the forks. How far would you say I have to be away from the header with the cooler?

gotgixers
04-15-2009, 07:26 PM
.250 to .375 inch.

jakegsxr11
04-15-2009, 07:27 PM
I don't mind working on it anyhow. My girlfriend has the hallway drywall in the house all textured and painted within the last couple of days so I got out of most of that!

jakegsxr11
04-15-2009, 07:27 PM
.250 to .375 inch.

That's it....I think I can make that work

gotgixers
04-15-2009, 07:28 PM
Well, the more you can get the better. But that is enough.

jakegsxr11
04-16-2009, 05:59 PM
Well guys....how does it look. I think It will work. :cheers Not bad for an amateur anyhow. Time to order up the B12 pan and pick up.

http://i699.photobucket.com/albums/vv355/ashleyls4825/100_1170.jpg

http://i699.photobucket.com/albums/vv355/ashleyls4825/100_1174.jpg

http://i699.photobucket.com/albums/vv355/ashleyls4825/100_1175.jpg

gotgixers
04-16-2009, 06:27 PM
It's great Jake. Did you happen to sit on the bike and try and bottom the forks while having someone watch for interferance?? You should do that before you hop on it and go ride...

wolfzero
04-16-2009, 06:32 PM
looks good enough how many people are gonna get there head in that close to see the bolts anyway :p

my bike has an aftermarket cooler so its not as tall as the oe cooler so is out the way of the headers :biggrin

my headers are bandit 12 so are a little tall for my 750 but they are better than the pos that was on :lol

long_av8r
04-16-2009, 07:38 PM
It's great Jake. Did you happen to sit on the bike and try and bottom the forks while having someone watch for interferance?? You should do that before you hop on it and go ride...

+1, looks good, but definately do what GG said. You don't want to find out the hard way...

koolaid5
04-16-2009, 08:14 PM
Nice Job Jake..

and Wolf....those are purty and shiny :banana

jakegsxr11
04-16-2009, 08:32 PM
Thanks guys. I will check the clearance while compressing the forks. I never thought of that, good idea.

gotgixers
04-16-2009, 09:37 PM
Your welcome, some of us have learned the hard way...back in the day....it'll stuff a front fender and mess your day up REAL fast. Dont want to see that happen to you.