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Old 12-06-2010, 01:41 PM   #1
ANDRASTA
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k3 GSXR 1000 header on 96 GSXR 1100 write up.

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.

Seating perfectly.



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??
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Old 12-06-2010, 01:43 PM   #2
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

Two more....





If you guys need me to take more upclose pictures using my regular cam I can , just let me know,.
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Old 12-06-2010, 02:52 PM   #3
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

GREAT info, Can't wait to see how it looks on the bike

What is the weight differance between the two?
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Old 12-06-2010, 03:03 PM   #4
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

Fantastic info!

Couple of questions for you:

1) Did the K3 header come with a cat?

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...

Many thnaks,

Seb

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Old 12-06-2010, 04:26 PM   #5
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

I can tell you that the 2003 GSXR does not come with a cat
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Old 12-06-2010, 05:37 PM   #6
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

Quote:
Originally Posted by Sabba View Post
Fantastic info!

Couple of questions for you:

1) Did the K3 header come with a cat?

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...

Many thnaks,

Seb

NP Sabba.

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.
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Old 12-06-2010, 05:38 PM   #7
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

Quote:
Originally Posted by Mr645 View Post
I can tell you that the 2003 GSXR does not come with a cat
Correct Sir, just has some butterfly thingy, Probably something to do with cold starting and the fuel injection???

I can remove the butterfly plate or just cut the whole thing off and JB weld the hole.
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Old 12-06-2010, 05:48 PM   #8
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

Thanks so much!

And I think you are refering to the SET valve, which is mainly there for sound-dampening (somebody correct me if I'm wrong here)...

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Old 12-07-2010, 12:36 PM   #9
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

Quote:
Originally Posted by Sabba View Post
you are refering to the SET valve, which is mainly there for sound-dampening (somebody correct me if I'm wrong here)...
It's really Suzuki's take on the Exup valve Yamaha came up with
(once their patent had run out of time, of course).

Sound deadening is a handy spin-off but it's really supposed to boost the bottom end & mid-range pull
(something Gsxr1000's - esp the K1 - K6 versions have no problem with anyways).
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Old 12-07-2010, 01:32 PM   #10
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

cool.......
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Old 12-07-2010, 02:09 PM   #11
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

One more question:

If you were to chop off the mounting plate for the stock muffler, what is the outer diameter of the end of the midpipe?

Just want to see if my current slip-on would fit...

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Old 12-07-2010, 09:26 PM   #12
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

Quote:
Originally Posted by Sabba View Post
One more question:

If you were to chop off the mounting plate for the stock muffler, what is the outer diameter of the end of the midpipe?

Just want to see if my current slip-on would fit...

NP,

Circumference measured at 6.25 inches = 1.989 inches Diameter hence, Diameter is 2 INCHES.
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Old 12-08-2010, 01:23 AM   #13
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

Quote:
Originally Posted by 1996GSXR1100 View Post
NP,

Circumference measured at 6.25 inches = 1.989 inches Diameter hence, Diameter is 2 INCHES.
Thanks!
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Old 01-08-2011, 05:02 PM   #14
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

Thanks for the write up. I was about to give this a shot. I may modify for a dual exhaust though.
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Old 01-10-2011, 08:11 AM   #15
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

If you guys are willing to wait till next tuesday, I should have the header on along with the stock muffler and gonna see how clearances are with the fairings.

I dont think there will be any clearance issues.
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Old 01-10-2011, 09:36 AM   #16
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

Cool post. Giving me ideas! Cannot wait to see the finished product.
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Old 01-11-2011, 11:22 AM   #17
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

could you use a slip on that just barely pokes out from the bottom of the bike near the frame, like the smaller m4 mufflers?
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Old 01-11-2011, 04:42 PM   #18
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

Quote:
Originally Posted by mdillon View Post
could you use a slip on that just barely pokes out from the bottom of the bike near the frame, like the smaller m4 mufflers?
I dont see why not. Im planning on putting an alien head on mine
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Old 01-18-2011, 10:15 PM   #19
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

Sorry for the delay guys, Ive been quite busy.

I think this weekend coming for sure.
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Old 01-18-2011, 10:50 PM   #20
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Re: k3 GSXR 1000 header on 96 GSXR 1100 write up.

What other years would fit similarly? 01-06?
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