First off, let me say a big thanks goes to our forum member Sid ( SINBIN) who allowed me to borrow and use his spare engine head in order for me to have the pipes bent correctly.
Ok, on with the write up.... Sorry for the crappy cell phone shots.
So I was refered to Majestic Muffler by my local mechanic Charlie ( Pro performance automotive). He let me know they were in the business of mufflers and pipe bending etc. and that they would be a good option.
Off I went. Majestic Muffler is located on 6462 Kingston Road, Toronto, ON.
I asked for Frank (Owner) , he came out,took a look at the pipe and told me to grab the engine head and come into the shop area.
Right away two of his guys were interested in doing the work. Much thanks to the two guys Brenden and Hugh ( Hugh is HUGE!! doesnt look like he even needs a pipe bender for exhausts!!)
First off the Guys secured the #3 and #4 ( left to right sitting on bike) Pipes, as the space on the pipes was already correct , they bolted right up. The bolts used were 8X1.25.
You can see here, 3 and 4 are secure and 1 and 2 are slightly off.
As you can see,#3/4 slide in perfectly.
Next , Once #3 and #4 were secure , Hugh slowly pulled on pipe #1 and #2 at the same time and put them in their respectful hole.
As there was tension on the pipe, both the guys went around torqing all the bolts evenly.
A problem that SinBin ran into was canting of the pipe. As the pipes on #3 and #4 were already secure this problem was avoided. I think this was the most important step was to make sure 3 and 4 were bolted down first.
Next Brenden slowly applied heat using a torch for about 5 or so minuites. He went slowly and evenly until it was a light red. He applied heat to only the bend at the bottom of the pipe. He explained as the titanium was very brittle he had to go slow and very evenly as there is a high risk of cracking.
As explained, heat was only applied to the bend at the Y- Pipe on the left side of collector.
After the heating was done it was just left to cool for about 10 Minutes.
Hugh unbolted it for me when it was cool. The pipe only went back about 1mm at the most. He said that when I bolt it up , put some high temp silicon on the inside of the holes just to be sure and after riding the bike for the first time retorq all the bolts and maybe periodically check on it when I do an oil change. The heat in the headers will eventially make the whole header relax completely.
$40 Bucks out of my pocket to Frank, and I was on my way home.
The finished product.....
Hey MODS!! Can you make this my first Sticky thread??? What you say guys??
2) Any chance of seeing the actual weight differences? (I imagine they are quite drastic)
3) What are the differences in Interior Diameter between the two headers? (Will a rejet be necessary?)
4) Any issues with oil pan (or filter)/fairing clearance?
And a favor to ask of you:
Could you provide the spcaing measurements of the header tubes...I would like to see if this is a possible swap for a 750...
1) The K3 header does not have a Cat, The pipe that came with it ( Stock )just has some butterfly thinggy heh. I will have to remove that if I want to run the stock/quiet pipe. If you check out my old thread you can see photos of the complete stock unit when I got it. http://www.gixxer.com/forums/showthr...110&highlight=
2) The difference between both systems complete is about 30 to 35lbs. The K3 header weighs exactly 2183 grams, which is 4.81 lbs .
3) The interior diameter appears to be the same, the K3 header might be a bit larger as the tubes flare a bit after exiting the engine head. I can tell you this Sabba, when you hold the header in your hand, the bends are so smooth and bent so well that you can tell there is soo much better airflow. Just by looking I have to say though it looks like the K3 header might be a 1/8 to 1/4 inch larger on the inside diameter.
My bike runs a tiny bit rich right now. I dont think I will need a rejet. I dont think anyone would need a rejet unless they are running lean already.
4)I havent had it on the bike yet, but looking how it lines up I think it will actually give me MORE clearance as this pipe will likely hang down an inch lower near the oilpan area than the stock unit. If you look at the photo of the header overlaping the old one, you can see that the pipe takes the same path and the drain bolt on the 1100 is behind the xpipe on the stock unit.
5)Not a problem, without measuring , I can tell you this infact will fit on a 750 as the engine head I used was from a 750. My understanding from SID was they are infact the same spacing from 93-98 model years. Picture #10 on the first posting showes the 1100 stock header on the left, as you can see, its exactly the same dimensions as the header was bent to a 750 head.
Either way , the dimensions are exactly 3.5 Inches between pipes #2 and #3.
Anymore questions, feel free to ask, I have both systems off the bike in the livingroom haha.