HOW TO: Headers swap 600 vs. 1000 (PICS) : Suzuki GSX-R Motorcycle Forums: Gixxer.com
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Old 11-11-2010, 03:05 PM   #1
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Headers swap 600 vs. 1000 (update more pics)

Hello! Hello!.. Welcome to the thread of Headers! I am going to be teaching you today on a HOW TO:

The 05 STOCK Headers+midpipe 600 is heavy.. The 03-04 GSXR1000 headers is light.. I was surprised.. I cannot believe the frickin diffrence from STEEL headers VS. Titanium headers. The weight advantage is a big huge diffrence... You shaved off maybe 15-20 lbs. in weight.. I don't know. Just using my head.. I don't have a weight scale to check.

This mod is 6 on scale of 1-10 easy to hard. It should last you prolly 1-2 hrs. depends on how fast or slow you want to do it. All i did was take my time and everything went smoothly. After everything is done, you will have to modify your fairings, so the exhaust wont touch and melt it.. If you go to the second page on this forum, you will see how i modify my fairings. It don't take much to do and it works real good. Bolt nuts and washers.


Taking old headers off-

You take BOTH fairings off.. Alot of room.. You can use "PB Blaster" or WD-40 to the headers bolts.. let it soak in for like a mins, so you can unscrew those ungodly, nasty, rusted 6mm allen bolts off.. You can skip this step if you want. But, they are hard to get off, if you dont. Take a Long torque bar at it. Then you can unscrew the 10mm at the lower part of the radiator. take the screw out. then you UNscrew the 2 top 10mm bolts on the upper radiator,. Don't take them out.. just loosened it up to where you can move the radiator out towards your front fender. Then grab something you can put in between the radiator and its mounting bracket to keep it coming back down on ya, when your unscrewing the allen bolts off the headers. I grabbed a lil fuse box i found in the garage and used that for this part.. you can see in the pics.. It gave me enough room to unscrew all the headers ALLEN BOLTS out.. I did this very very carefully.. "GO SLOW, TAKE YOUR TIME". dont hit your radiator FINS.. you can bend them easily.. You can always use a small flathead screwdriver to make them straight.. After you take all 8 Allen bolts out, But, before you take your 600 HEADERS OFF.. You need to go where that 12mm bolt is right by your FOOTPEGS and take that off first. before you drop the headers down... THEN "Slowly drop your 600 headers down and SLOWLY pull it out".. Feel How heavy that Son of a bitch IS.. DAMN!

Putting the NEW Headers on..-

I got some extra GASKETS i found in my garage from when i had my 03 600, i was putting full exhaust on.. So i grabbed 4 new GASKETS.. I took 4 of the old ones out.. You can put 4 new ones in or you can keep your old ones you have now, and reuse them.. Then you take the Titanium Headers and "SLOWLY put it up to the gaskets". I put "BLUE" Loctite on the allen bolts When i put them back in.. You can do this, if you want to.. You dont have too. But, in the future they might loosen itself up from all the riding and WOT. Exhaust LEAKS sucks. So, After You put all the bolts back in and hand tighten all of them til the headers seats to the gaskets you put in.. Once all that is done, You proceed to tighten all the allen bolts starting from the middle and work your way out.. i tightened them all down to 16.5 ft. lbs. when i did it, cause thats what the OWNERS MANUAL says to do.. OR you can handtighten them yourself or whatever.

Thats it..

how it should look when both right and left fairings are off the bike..



OEM 600 headers + midpipe


Your 600 headers + midpipe together vs. 04 GSXR 1000 headers only- no midpipe.


the fuse box i use to space it out.. (You can use whatever you want to space that out)


Old Gaskets which is kept. and (8) headers allen bolts


The 04 GSXR1000 Titanium headers on the bike.. (How it should look after everything is done)


Your Gixxer owners manual, old gaskets on bottom, new gaskets Vesrah on top (if bought)

Last edited by I'm-a-punk; 12-10-2010 at 07:34 AM. Reason: more pics.
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Old 11-11-2010, 03:08 PM   #2
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

Continued

The Tools you'll need! left to right (Torque bar, Torque Spec Bar Rachet, Socket rachet, Long extender w/ swivel, Short extender w/ swivel, Allen key 6mm, Allen 6mm socket, Allen key with mutiples)


Where the end of the headers comes to


Thats where it stops to the mid pipe.. right under the 12mm hole


The K3-K4 stock midpipe you'll need. The GSXR tire valves and Midpipe are from member here "CHITOLOVE".. Thanks bro! IF you get a Midpipe with a "SERVO sensor" on there, you will need to delete it. Also, you will need to take out the "BUTTERFLY valve" inside the midpipe and (JB WELD) the Hole!


The Midpipe at the end of the headers.. Its not on there.. its put up next to it. Looks real nice!


The 12mm bolt on the side by the footpegs will not line up.. Its okay though. You can either make a bracket yourself, or You can put the strap back on, which i did.. it holds it tight, no vibration, or movement.. It misses the hole by couple inches...


Bolt on whatever pipe you want.. -YOUR CHOICE- Make sure it has a strap though so it can hold it in place and tight..


The Finish look... With the Yoshimura Bolted-on


Enjoy the Sound/Performance/Weight/Looks


Last edited by I'm-a-punk; 12-10-2010 at 07:33 AM.
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Old 11-11-2010, 03:26 PM   #3
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

shoulda got some dyno #'s before and after. But cool nonetheless. The weight drop is plenty noticeable I bet....30lbs is a lot.
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Old 11-11-2010, 05:48 PM   #4
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

this is probably a stupid question but can you run that with out a pc3 and tune?
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Old 11-11-2010, 06:03 PM   #5
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

yes but it would be better to have a custom map installed when tuned.
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Old 11-11-2010, 07:03 PM   #6
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

Yeah the weight savings is noticeable I saw your other thread so I did my swap last night . the sound is a little better and the bike just runs a bit better . I will post a pic after you dont want to thread jack .
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Old 11-11-2010, 07:42 PM   #7
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

so this is just a bolt on and go mod; after a PCIII and tune?
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Old 11-11-2010, 08:35 PM   #8
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

Quote:
Originally Posted by 600k2 View Post
so this is just a bolt on and go mod; after a PCIII and tune?
Yeah it is but you need to get some heat wrap for your lower as the new header sits lower .
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Old 11-11-2010, 09:22 PM   #9
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

Quote:
Originally Posted by Smittybizzle View Post
Yeah it is but you need to get some heat wrap for your lower as the new header sits lower .
Its called WASHER MOD.

Last edited by I'm-a-punk; 12-10-2010 at 07:36 AM.
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Old 11-12-2010, 01:52 AM   #10
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

While I know it's lighter, I don't see a 30lbs reduction, though this swap has me intrigued.
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Old 11-12-2010, 06:02 AM   #11
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

about 15-20 lbs. reduction at the most,

Last edited by I'm-a-punk; 12-10-2010 at 07:36 AM.
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Old 11-12-2010, 06:39 AM   #12
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

Quote:
Originally Posted by 600k2 View Post
so this is just a bolt on and go mod; after a PCIII and tune?
Yes, it's a straight bolt-on. I would get a k5/k6 1000 header though. You can find them on ebay for $100 or less.
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Old 11-12-2010, 07:15 AM   #13
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

It's a bolt on swap, but it's mainly a weight reduction + more exhaust options. You don't have to buy a PCIII just get your stock ECU remapped.

Quote:
I would get a k5/k6 1000 header though. You can find them on ebay for $100 or less.
Looking at the pictures of K1-K4 and K5/K6 headers they look pretty much the same.
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Old 11-12-2010, 09:16 AM   #14
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

Quote:
Originally Posted by MikeSuzuki05 View Post
Its called WASHER MOD.
Yeah for the side where the mid pipe goes but your lowers will need heat wrap mine have started to melt a little so I will tend to it in a little while . Trust me .
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Old 11-12-2010, 09:49 AM   #15
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

Just for the record:

NEVER NEVER NEVER wrap titanium pipes!
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Old 11-12-2010, 12:18 PM   #16
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

i agree with TheGeek.. thats why im not wrapping the headers, because it's Titanium. You do not want to mess up that nice (Bluish-Purplish look).. It makes the bike look even more sexier!

Last edited by I'm-a-punk; 12-10-2010 at 07:36 AM.
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Old 11-12-2010, 04:59 PM   #17
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

Awesome write up wish i had this write up before I did mine. Good job Mike bike looks sick.!!!!!!!!!
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Old 11-12-2010, 05:28 PM   #18
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

Iam not gonna remap it b/c I just like the look of a slip on vs the ugly bolt on style . I will be doing my 1000 swap within a few weeks or so just finishing up the rebuild she is gonna fly .
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Old 11-12-2010, 06:30 PM   #19
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

Theres no need for re-map... But, i will get a custom tune anywayz..

The sound is awesome.. more growly, more loud, more clean and crisp..

This mod is a MUST DO.. You guys will love it.

Last edited by I'm-a-punk; 12-10-2010 at 07:36 AM.
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Old 11-13-2010, 02:25 PM   #20
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Re: HOW TO: Headers swap 600 vs. 1000 (PICS)

you will have to make couple spacers on your fairings.. No biggie though..

I did spacers and zip ties on my fairings.. No melting.. All is WELL.. yay!!!

If anyone have any questions? Let me know.

Last edited by I'm-a-punk; 12-10-2010 at 07:35 AM.
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