900rr header woes... - Wrist Twisters
 
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post #1 of 36 Old 05-02-2015, 12:46 PM Thread Starter
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900rr header woes...

Hey guys,

im trying to do this 900rr header conversion but am running into some trouble. The headers dont fit flush on the heads, the top will sit in but the bottom sticks out. It seems like that bar that runs horizontally in front of the motor is obstructing the header from seating properly.

i've tried bending the header all sorts of which ways (as minimal amount as possible) and cant get it to seat.

did i get the wrong headers?

googlit did mention in one of his videos that not as much of the header goes into the head... but damn if it doesnt seem like thats not an airtight fit.

im going nuts over here!
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post #2 of 36 Old 05-02-2015, 01:00 PM
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Hmm. Mine certainly bolted up very firmly in to place.

What's stopping the alignment? Is the collector part coming up against the bottom of the motor and holding the pipe down, or just the bar? Are there any brackets on that part of the pipe?

Before I began I read on here of others having to give that part of the pipe [where it contacts the bar] a discreet bit of a crush to make everything fit...Wasn't the case for me, but I did read about it....

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post #3 of 36 Old 05-02-2015, 01:07 PM
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I have done a few 900rr conversions and never seen one like that. Are you sure its a 900rr header?

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post #4 of 36 Old 05-02-2015, 01:44 PM
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I'm also curious... I have a yoshimura and a two bros header for an RR, both fit easily. Is this a delkevic?

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post #5 of 36 Old 05-02-2015, 01:53 PM Thread Starter
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im starting to think its not... it just wont line up! so close to snapping head studs and bolts trying to get this thing in. im stepping away from it for a bit

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post #6 of 36 Old 05-02-2015, 04:52 PM Thread Starter
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I was told they were vance & hines, i might/possibly could notch em but im not sure that would solve the problem

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post #7 of 36 Old 05-02-2015, 06:25 PM
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If they are not OEM 900rr headers, then the fitment may be off enough to not allow it to work.

The OEM frame may not have been as close (or extended) as the 900rr frame, and V/H may have known that and modified their fit a bit.

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post #8 of 36 Old 05-02-2015, 07:16 PM Thread Starter
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Quote:
Originally Posted by g00gl3it View Post
If they are not OEM 900rr headers, then the fitment may be off enough to not allow it to work.

The OEM frame may not have been as close (or extended) as the 900rr frame, and V/H may have known that and modified their fit a bit.

hey googlit, yeah that makes sense. bikes all apart now, im not putting the stock exhaust back on i need to find a 900rr header i can use

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post #9 of 36 Old 05-03-2015, 04:09 PM Thread Starter
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So i found the tag that had the model # Vance & Hines V14511 - which is a set of 93-99 900RR headers.

I test fit them again today, looks like the 2 inner pipes will work, its just the 2 outer ones getting obstructed by that bar in front of the motor. I need an extra 1/2inch clearance to get them in. Im thinking/hoping/praying (sacrificing small animals) that if i knotch the two outer pipes i can get that 1/2 inch.

what do you guys think? Ive never done anything like this before and i'd hate to destroy these headers

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post #10 of 36 Old 05-03-2015, 04:26 PM
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Check this thread. They talked about having to hammer some flats in the header to clear the bar for some earlier year 900RR headers.

Good luck!

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post #11 of 36 Old 05-03-2015, 04:30 PM Thread Starter
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Quote:
Originally Posted by marylandmike View Post
Check this thread. They talked about having to hammer some flats in the header to clear the bar for some earlier year 900RR headers.

Good luck!

thanks MM - not sure if im ready to take this plunge yet or not. have doubts it will give me enough room.

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post #12 of 36 Old 05-04-2015, 10:41 AM Thread Starter
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what are your guys thoughts on possibly using a small tube spacer in the heads? i would just need a 1/4 - 1/2" tops

bad idea?

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post #13 of 36 Old 05-04-2015, 11:27 AM
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Sounds like asking for leaks. And a PITA.

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post #14 of 36 Old 05-04-2015, 11:31 AM Thread Starter
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Quote:
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Sounds like asking for leaks. And a PITA.

yeah... i know. im going to try notching the headers tomorrow and see if that gives me enough room.

im partially worried that even if i get a good fit on the heads, the headers will be pressed so tight to that bar that when i ride and hit a bump or something im going to possibly loosen or break them

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post #15 of 36 Old 05-07-2015, 03:45 PM
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Any update with header fitment?

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post #16 of 36 Old 05-07-2015, 04:18 PM Thread Starter
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hey Nick, still working on it. Bought ANOTHER Vance & Hines header in black, kinda rusty so the guy just gave it to me after i explained the trouble i was having with the first one.

I kinda have throw in the towel though: i brought the black 900rr header and my stock header to an exhaust shop. I asked the guy to cut the outlets off both headers and weld the 900rr outlet to the stock one. I had two exhaust shops tell me they couldnt do it. The last guy took it, is going to look at it and decide if he can do it. Here's hopin....

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post #17 of 36 Old 05-20-2015, 04:06 PM Thread Starter
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update, cut off the ends off the aftermarket 900rr header and the stock header. Had the outlet from the aftermarket 900rr header welded to my stock header. below is the result. working on getting the intermediate pipe mocked up and a bracket welded to it.

i've been told to be careful how/where i weld the bracket to either the intermediate pipe or header outlet as if its not welded in just the right spot - when it is bolted to the bike it will torque and stress the welded on outlet which will eventually break.
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post #18 of 36 Old 05-21-2015, 05:55 AM
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I'm still confused as to why it didn't work the first time; I've had the stock 919 header, stock RR, Yoshi, and now a TBR header and all dropped in without a problem. But alas, you are getting creative and making it work! Keep it up!

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post #19 of 36 Old 05-21-2015, 07:33 AM
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I'm still confused as to why it didn't work the first time; I've had the stock 919 header, stock RR, Yoshi, and now a TBR header and all dropped in without a problem. But alas, you are getting creative and making it work! Keep it up!
Some of the aftermarket 900RR units don't clear the crossbar on the 919 frame, it would seem. My brother ran into exactly the same problem with his when the seller failed to indicate it wasn't an OEM unit. I'm not sure exactly which manufacturers don't fit, but it seems like the safe bet is to just stick with OEM. Those work every time

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post #20 of 36 Old 05-21-2015, 11:07 AM Thread Starter
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Quote:
Originally Posted by BockHawk View Post
Some of the aftermarket 900RR units don't clear the crossbar on the 919 frame, it would seem. My brother ran into exactly the same problem with his when the seller failed to indicate it wasn't an OEM unit. I'm not sure exactly which manufacturers don't fit, but it seems like the safe bet is to just stick with OEM. Those work every time

YES, exactly this. Both 900RR headers i bought were made by Vance & Hines (what are the odds?) V&H made the headers for the 900rr... they built them to spec to fit the 900RR which didnt have a crossbar in front of the motor so V&H could just straight drop the header tubes down without any thought of clearing anything. It looks really nice and would have complimented the 919 well if it fit... really hugged the motor.

Oh well, we'll see how this thing works. I am a novice with this cutting/welding stuff so im figuring out what i need to do and bringing it to the exhaust shop to do the cutting. I'll keep everyone updated.

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post #21 of 36 Old 05-21-2015, 07:13 PM Thread Starter
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question on this... both the inlet and outlet have those little tabs that the tension springs attach to, is thats all that needed to secure these two pipes together? it cant be...

if its not anyone have any recommendations to secure these two peices short of welding these two pipes together?
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post #22 of 36 Old 05-22-2015, 05:57 AM
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That is correct! Then your muffler should have some type of clamp mount as well.

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post #23 of 36 Old 05-22-2015, 09:01 AM Thread Starter
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hi scrat,

thanks a lot! im surprised though, the intermediate pipe slips over the outlet... and is somewhat snug but it seems like it wont be airtight,

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post #24 of 36 Old 05-22-2015, 11:32 AM
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carry on, put high temp sealant if your worried, but the springs are good to go if everything fits tight and isn't stressed.

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post #25 of 36 Old 05-24-2015, 08:42 PM Thread Starter
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just wanted to give an update, getting the final bracket welded on and i'll take some pics.

i was able to get the ypipe out, i followed googl3its youtube video on how he did it. really easy, glad i saved it rather then cutting.
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post #26 of 36 Old 05-25-2015, 10:26 PM
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Quote:
Originally Posted by SGKukov View Post
just wanted to give an update, getting the final bracket welded on and i'll take some pics.

i was able to get the ypipe out, i followed googl3its youtube video on how he did it. really easy, glad i saved it rather then cutting.
Glad it helped. The hardest part is just getting the bike suspended.

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post #27 of 36 Old 05-27-2015, 05:56 PM Thread Starter
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so the conversion is done(ish), finally got the bike roadworthy and it feels GREAT to get her out.

i know the style muffler i used and the angle isnt everyones cup of tea but i like it. if anything i might want to shorten the exhaust a bit.

still need to take the pipe off and paint it and fiddle with some things a bit. feels like fuel mileage has suffered but... im not entirely sure on that.

working on a bracket to attach to the rear set to make it super stable... and that should be it.
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post #28 of 36 Old 05-31-2015, 07:19 AM
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nothing like a completed project especially if you are happy with it.

for those where it ain't their cup of tea, and they wouldn't steep their tea this way, they can go shtup their tea somewhere else.

that open undertail look on the 9er is quite unique...with the finish on your pipe, creates two black lines framing top and bottom...pretty cool...

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post #29 of 36 Old 05-31-2015, 10:13 AM Thread Starter
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Quote:
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that open undertail look on the 9er is quite unique...with the finish on your pipe, creates two black lines framing top and bottom...pretty cool...

yeah i really like the look, originally it was being done so i could do the hard saddlebags like MarylandMike has... which i am still going to do

however after doing it i REALLY like the look of no exhaust on the undertail. pictures of all these low mount exhausts are misleading, the tail looks strange in the pictures like there is too big of a gap between the wheel and tail, but in person you never notice it, it just looks right.

some strange things though... after doing the exhaust i can go lower in RPM's without the engine stalling, i drop it down to like 600rpms. Feels less jerky shifting at lower speed / lower rpms, not sure why this is. Don't notice (and didnt expect to) any increase in power... possible small loss in top end but im not entirely sure on that. i have a PCIII but am still running the same map i did when i just had a debaffled stock exhaust.

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post #30 of 36 Old 05-31-2015, 10:38 AM
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maps are pretty sensitive, there's probably one specific to your set up available on this site.

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post #31 of 36 Old 05-31-2015, 11:32 AM
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looks great but avoid riding it until you finish the rear bracket.........trust me.

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post #32 of 36 Old 05-31-2015, 07:58 PM Thread Starter
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Quote:
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looks great but avoid riding it until you finish the rear bracket.........trust me.
ahhh... after hearing that i wont, i was already worried i might be getting greedy taking it out like that.

are you speaking from personal experience?

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post #33 of 36 Old 05-31-2015, 11:06 PM
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I can speak from experience!! I have had more than one header fail from and lack of support operator error is the ulfimate nemesis!

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post #34 of 36 Old 06-01-2015, 08:48 AM
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tires, brakes, battery and exhaust don't need help to wear or fail prematurely. every bump you hit and every heat/cool cycle stresses the attachment points in all directions.

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post #35 of 36 Old 06-02-2015, 04:11 PM
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Looks good. Id still like to use stock header and modify it to single sided exhaust.

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post #36 of 36 Old 06-04-2015, 05:24 AM Thread Starter
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Quote:
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Looks good. Id still like to use stock header and modify it to single sided exhaust.

thats what i had to do. here's a pic. i like it and i think there are little resonators in the 919 header that help to quiet the exhaust down so my use of this typically loud muffler isnt that loud
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