R6 header advice

[Skaterbro]

I highly advise getting the 2nd gen headers(2003-2005 iirc) over the 1st gen. You can fit headers from a first generation r6(1998-2002) on this bike but they touch the oil pan causing exhaust leaks so you have to bend or beat the crap out of them. Also make sure the slip on fits. You will probably need a sleeve or mid pipe for it

 

[Marthy]

Yep! Been there, done that! LOL

That was my first exhaust mod and it took me longer to mod the R6 exhaust to fit than modding a 6R exhaust.

 

[Skaterbro]

Yep! Been there, done that! LOL

That was my first exhaust mod and it took me longer to mod the R6 exhaust to fit than modding a 6R exhaust.

How did you work out fitting the r6 headers? Did you bend or smash or both?

 

[Marthy]

How did you work out fitting the r6 headers? Did you bend or smash or both?

I end up cutting it and redoing the end to fit properly. I did end up selling it modding the FZ6R headers. thats how I end up building a bunch for many forum members.

 

[audace]

How did you work out fitting the r6 headers? Did you bend or smash or both?

I picked up an 03-05 R6/06-09 R6S oil pan and swapped it out. No need to modify the header that way.

 

[Skaterbro]

I picked up an 03-05 R6/06-09 R6S oil pan and swapped it out. No need to modify the header that way.

Neat. I knew they should technically fit but I didnt want to chance it myself and just banged the pipe and my head a lot instead

 

[audace]

Neat. I knew they should technically fit but I didnt want to chance it myself and just banged the pipe and my head a lot instead

Yeah, I feel you on that. Hammer modification is free too!

But if you ever do want to swap it out, it's just an R6 oil pan, R6 oil pan gasket, and one extra oil pan bolt. The R6 pan uses one additional bolt right in the center of the pan, but it's not an issue since the FZ6R block still has that threaded hole there even though it's not used.

 

[Skaterbro]

Yeah, I feel you on that. Hammer modification is free too!

But if you ever do want to swap it out, it's just an R6 oil pan, R6 oil pan gasket, and one extra oil pan bolt. The R6 pan uses one additional bolt right in the center of the pan, but it's not an issue since the FZ6R block still has that threaded hole there even though it's not used.

Thats great to know. I'll probably do that when I have money again lol. In the meantime I have just been getting the pipes red hot and slowly bending them as much as I can while its on the bike to try and get more than 1/8th inch clearance.

 

[audace]

Thats great to know. I'll probably do that when I have money again lol. In the meantime I have just been getting the pipes red hot and slowly bending them as much as I can while its on the bike to try and get more than 1/8th inch clearance.

Oh for sure. The oil pans are pretty cheap and easy to find too. I picked mine up off eBay for like $30.

If you want to see anything specific about it, there's pictures and whatever I wrote about it in my build thread.

 

[Skaterbro]

To anyone who is still looking around... i would rate this project a PITA and would recommend just doing the marthy mod lol. That or get the 2nd gen headers.


After I finally got the 1st gen headers on with enough clearance I ran into many other problems(which would be resolved by a "straight pipe" muffler). My muffler didnt fit because it hit the brake pedal. Eventually I got a mid pipe meant for an r6 but that is long enough I couldn't clamp the muffler to anything and the only position it fit without causing issues when leaning was kind of weird.(see attached pic)

Because of this weird positioning I couldn't attach a clamp so the whole system ended up slowly falling sideways after about 20 minutes of riding(it also screamed like a tea kettle after it made it about 15 degrees because it F'd the muffler sleeve up lol)

Since I'm already going to need it for most jobs I'm looking into I'm just going to pick up welding and make a marthy system as a learning experience

 

[Skaterbro]

Another couple of notes...

1. Probably best to put something soft under you tank when leaning it on the seat(see pic 1)

2. Just get some cheap smog block offs from aliexpress or something the ones made for the r3/r6/fz6/r1 are exactly the same and fit like a glove. Its not worth the $89-$119 other suppliers are trying to sell them for.

I had ordered smog plates and got an email later saying the price was wrong and they would charge $119 unless I canceled the order(Wtf).

The ones I got are generic "fz6r smog block off plates" from china and cost me $12 but are surprisingly good quality(see Pic 2)