FINALLY! 900RR Header conversion DONE! - Wrist Twisters
View Poll Results: What do you think of my new setup?
I think you just rocked my world... 29 49.15%
You had Sato pipes and you SOLD THEM? Death to you! 18 30.51%
What is a header? 4 6.78%
If she ain't stock, she ain't purdy... 10 16.95%
Multiple Choice Poll. Voters: 59. You may not vote on this poll

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post #1 of 53 Old 08-30-2010, 08:19 PM Thread Starter
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FINALLY! 900RR Header conversion DONE!

I promised pics when I got this project done, so here are two picture galleries, as well as videos of how I did the install. I thought it was better to youtoob it than to just post pics all in a row here in the forums.

Pictures have captions of what is in the picture (parts, names, etc.)

Pic thread 1

Pic Thread 2

Random Pic thread

Stock pics thread

Youtube videos:

My Channel

900RR Header install videos (there are 4):




Full Video of mods and current state of bike:

Other videos:


(the Sato pipes I had before the 900RR conversion; I still miss them sometimes , but the overall conversion fun factor was worth it)


Anyways, it took me a while to take all the videos, edit them, get the pictures taken, etc. I wanted to document at least most of it to show how I did it, and that it was a lot easier than I thought (I have good contacts though *ahem* WT).

Thanks goes to all who have done the 900RR conversion; your input was invaluable. Thanks to MarylandMike for the template on the can mount (even though I was able to fabricate my own). Thanks to Ebay guy for the Headers. Thanks to 3cycle.com for price matching the carbon fiber Scorpion can.

Thanks also to Rocky Mountain Powder Coating (Powder Coating Pocatello, ID - Rocky Mountain Powder Coating). Mike, you do an AWESOME job! He also did the ceramic coating on my pipes and was generous enough to weld my brackets for me. Great customer service.

I do plan on getting a better video with me moving on the bike. Hopefully with a better camera than just my phone.

Thanks again for all the help, guys, I'm LOVING this setup.

And just to add a little more evidence to the pile, I DEFINITELY feel a performance increase with this new setup. I already had the PCIII USB, just with Sato pipes and appropriate map. I have not had it Dyno'd yet, but it is already easier to lift the front and she rockets like crazy!

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post #2 of 53 Old 08-30-2010, 08:22 PM Thread Starter
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Don't forget to take the poll at the top!

...and before anyone has a chance to poke fun, YES, I was wearing socks with my sandals in my garage.

It was cold enough to warrant such an act, and I'm over 30, so style went out the window already. With me. Not the bike, of course.

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post #3 of 53 Old 08-30-2010, 08:34 PM
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Man, I've been waiting to see how it turned out and thinking what the heck is taking so long. Now I see why! Wow great job of documenting the process. It looks great with the CF can and coated headers and sounds great.

Absolutely first class job.

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post #4 of 53 Old 08-30-2010, 08:50 PM
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Great job, also thanks for recording it all.

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post #5 of 53 Old 08-30-2010, 08:56 PM Thread Starter
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Thanks guys, but I only did it so I could get rid of that ugly stock picture I had on my profile

Edit: even though it appears it hasn't change yet -

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post #6 of 53 Old 08-30-2010, 10:05 PM
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not my thing, but thst's some clean work. Nice! how you planning to sanitize the grab-rail holes?

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post #7 of 53 Old 08-30-2010, 10:07 PM
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Sounds awesome. Man, the blacked out swing arm looks sick.... I think I'm gonna have to do that.

What are you doing with the old sato's???

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post #8 of 53 Old 08-30-2010, 10:09 PM Thread Starter
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Quote:
Originally Posted by honda ng gingsa View Post
not my thing, but thst's some clean work. Nice! how you planning to sanitize the grab-rail holes?
Thanks! As for the grab rail holes, I plan on getting a set of grab rail caps, Rizoma probably, to match the rest of the bike. Anybody want to trade a powdercoated grab rail for their caps?

I have some G&J brake lines on the way as well, so those will be on in a couple of weeks after the dirt bike trip this weekend.

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post #9 of 53 Old 08-30-2010, 10:11 PM Thread Starter
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Quote:
Originally Posted by Wallybanger View Post
Sounds awesome. Man, the blacked out swing arm looks sick.... I think I'm gonna have to do that.

What are you doing with the old sato's???
Sold 'em to pay for the Scorpion :-)

I put them in the classifieds section and they were spoken for in a day or two.

Swing arm really wasn't that hard to take off. Worse part was cleaning out the bearings so grease didn't get in the powder oven.

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post #10 of 53 Old 08-31-2010, 02:13 AM
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Quote:
Originally Posted by g00gl3it View Post
Thanks! As for the grab rail holes, I plan on getting a set of grab rail caps, Rizoma probably, to match the rest of the bike. Anybody want to trade a powdercoated grab rail for their caps?

I have some G&J brake lines on the way as well, so those will be on in a couple of weeks after the dirt bike trip this weekend.
Yep, rizomas will work nicely. I've seen some nice solutions too by just cutting the rail and shaping the stumps nice and smooth.

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post #11 of 53 Old 08-31-2010, 07:03 AM
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That's a great looking set up (even for a red bike)

I'm currently running Yoshimura CF Tri-Ovals. While I really like them, I'm collecting parts as I find them for the same conversion. I picked up a header locally for $50 this summer. Perhaps when I get my garage done it will be a winter project for next year to give me something to do.

Great job, thanks for sharing

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post #12 of 53 Old 08-31-2010, 11:48 AM
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Bike looks sweet! That first wheelie on it kinda scared me. The power difference is amazing compared to my 9er. I am currently looking for my next upgrade!

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post #13 of 53 Old 08-31-2010, 11:57 AM Thread Starter
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Quote:
Originally Posted by OSIRIS View Post
Bike looks sweet! That first wheelie on it kinda scared me. The power difference is amazing compared to my 9er. I am currently looking for my next upgrade!
Osiris, I have to hand it to you for convincing me to get a 919 in the first place, otherwise I'd still be running my VTX.

Thanks also for all the help in disassembling the bikes and helping out; we got a lot done!

Where are the pics of your bike? eh? Time for you to show off, too!

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post #14 of 53 Old 08-31-2010, 12:12 PM
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Loves me a single sider with a shorty !

I was just musing today about making a pair of aluminum fuel tanks to put in the stock can spots for added capacity once one has gone solo on the exhaust.

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post #15 of 53 Old 08-31-2010, 12:16 PM Thread Starter
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Take that , LH, for putting ideas in my head.....

Ok, you first! Then show us all how you did it.

Then machine the parts and sell them to us for cheap.

I can see how this will work out very well...

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post #16 of 53 Old 08-31-2010, 12:22 PM
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Ha! Yeah. I'm remembering all the stuff TJ went through on his tiger. I'm looking at the slope of the cans and I'm thinking baffled with a vented cap...

but how to get the fuel UP to where it belongs...

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post #17 of 53 Old 08-31-2010, 12:24 PM Thread Starter
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Quote:
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but how to get the fuel UP to where it belongs...
Stoppies! What else!

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post #18 of 53 Old 08-31-2010, 12:29 PM
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Which is genius because no matter which way one is vertical there is always fuel supply !

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post #19 of 53 Old 08-31-2010, 12:48 PM Thread Starter
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While you're making these, don't forget to incorporate mount points for saddlebags. Might as well think ahead.

2009 Aprilia Tuono - Ginger
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post #20 of 53 Old 08-31-2010, 03:23 PM
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What year 900rr header fits a 2007 919? I see Delk sells them new for about 189.00. I want to do this conversion but I cant seem to find a used one.

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post #21 of 53 Old 08-31-2010, 03:56 PM Thread Starter
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Quote:
Originally Posted by vertical919 View Post
What year 900rr header fits a 2007 919? I see Delk sells them new for about 189.00. I want to do this conversion but I cant seem to find a used one.
Check here: 919/900RR Header Comparison - Wrist Twisters

I used a set from a '97 CBR. One major difference is whether or not the 4 into 2 pipe is welded or removable, and another is the end of the mid-pipe; does it end with a 3 bolt bracket, or as a slip on (just plain pipe).

I don't know which years have which format, I got the pipes first, then formulated a solution later. Once I knew that I had the one without the bracket, I knew a slip-on pipe was the best solution. The can I bought you can also get in a bolt on solution as well, so you could really go either route.

According to the thread above, and some other sources (just do a search for 900RR header on WT) I think the years 96-99 were preferred. Don't quote me though, find the source. If I find it, i'll post it.

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2006 Honda 599 - Ex wrecked it :-D
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post #22 of 53 Old 08-31-2010, 04:20 PM
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Nice setup... I really like all the powder coated parts.

How do you like the Rizoma indicators? I am looking to replace my blinkers.



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post #23 of 53 Old 08-31-2010, 04:30 PM Thread Starter
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Quote:
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Nice setup... I really like all the powder coated parts.

How do you like the Rizoma indicators? I am looking to replace my blinkers.

Love the Rizomas. All but the price, anyways. If you look closely in the pics, the back two cracked near the screw. I thought at first it was maybe a rock I had thrown up at them when they were mounted a bit lower, but then one on the front did it. I contacted the place I bought them from and they just said to send them back and they would replace them, and that they had never seen that before on the Rizomas, considered them top quality. I figured I had just got a bad batch; either that or they couldn't handle the niner 'vibes', lol.

Come to think of it, I wonder if they were both on the left side!? Can't remember.

They are bright enough, come with all you need to wire into stock wires (you have to do some soldering, of course, or crimp the ends). But they did have the resistors needed to convert down to LED requirements.

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post #24 of 53 Old 08-31-2010, 04:53 PM
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Googl3it, Very nice setup! Good pictures & vids, too! Looks like you're very happy with your new setup, i hope you get many miles of smiles out of it!







[Slight derail]

Quote:
Originally Posted by Lemonhead View Post
I was just musing today about making a pair of aluminum fuel tanks to put in the stock can spots for added capacity once one has gone solo on the exhaust.
LH, you are a bad, bad man! I had a similar idea a few weeks ago, but I was going to make one side a "tool tube" for storing stuff on trips. for the aux fuel tank, I got as far as thinking about the plumbing and decided a steel MSR fuel container would fit inside a 3" x 24" PVC pipe just fine. I went to Home Depot and bought two tubes and screw-off end caps for them and will get them mounted for a test run pretty soon! Let us know what you come up with if you decide to make actual fuel tanks, it's a very cool idea!

[/derail]

Well, fire the engines! Spur this iron space-pony on!

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post #25 of 53 Old 08-31-2010, 05:38 PM
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Went to my local t w tues and chatted with another rider (who liked the idea very much), we discussed letting one side be shorter so the pump could be located inside. Plus, with the downtube of the exhaust gone, there's plenty of room for whatever in there.

Trying not to get too excited. Gotta get my 900rr conversion done first.

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post #26 of 53 Old 08-31-2010, 06:51 PM
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That looks amazing. I love the can, I think thats my favorite one!! I cant wait to get my exhaust done here soon!

Also, Noticed the moto bike, Im just guessing....yamaha? yzf 450, 250???? NICE!

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post #27 of 53 Old 08-31-2010, 06:54 PM
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BTW: The bracket mount you did, WOW looks factory, and Im still drooling over the powdercoated swingarm and how it cleaned that up. I just may have to do that, man......Great job!

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post #28 of 53 Old 08-31-2010, 07:02 PM
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Quote:
Originally Posted by g00gl3it View Post
According to the thread above, and some other sources (just do a search for 900RR header on WT) I think the years 96-99 were preferred. Don't quote me though, find the source. If I find it, i'll post it.
Here was a thread that discussed the years.

https://www.wristtwisters.com/f94/wha...9-a-14804.html

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post #29 of 53 Old 08-31-2010, 08:28 PM Thread Starter
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Quote:
Originally Posted by TeamZ View Post
That looks amazing. I love the can, I think thats my favorite one!! I cant wait to get my exhaust done here soon!

Also, Noticed the moto bike, Im just guessing....yamaha? yzf 450, 250???? NICE!
'95 XR600R. Beast.

I used to have an '86, but the sucker almost busted my ankle on rebound compression. This one has a compression release in the stroke when kick starting it, so it won't bite back.

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post #30 of 53 Old 08-31-2010, 08:31 PM Thread Starter
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Quote:
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BTW: The bracket mount you did, WOW looks factory, and Im still drooling over the powdercoated swingarm and how it cleaned that up. I just may have to do that, man......Great job!
Thanks! It was a lot of fun, almost enough to do it all over again! Me and Osiris actually made videos of the bikes when we tore them apart to do the powdercoating as well. I'll try and get them on my youtube channel and post them here as well. Kinda weird seeing the whole back end of the bike off.

Quote:
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Here was a thread that discussed the years.

https://www.wristtwisters.com/f94/wha...9-a-14804.html
mmike, that was the exact one I was thinking of. That's where I got my info. Thanks!

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post #31 of 53 Old 08-31-2010, 08:57 PM
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Quote:
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'95 XR600R. Beast.

I used to have an '86, but the sucker almost busted my ankle on rebound compression. This one has a compression release in the stroke when kick starting it, so it won't bite back.
I was even close! damn

Those Xrs are awesome, just torque monsters! Very fun to ride.

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post #32 of 53 Old 08-31-2010, 10:50 PM
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Great work with the video.

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post #33 of 53 Old 09-01-2010, 03:27 AM
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Hey how do you find those turn signals - are they bright in the daylight? - some brands are not very clear in the day time. Thanks.

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post #34 of 53 Old 09-01-2010, 05:21 AM
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Absolutely brilliant, thankyou for taking the time to do this to help other people

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post #35 of 53 Old 09-01-2010, 06:44 PM
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I know it's tacky to ask about money... but I LOVE those ceramic coated/painted pipes. My header looks like crap, so I am thinking this might make a good winter project.

So how much am I looking at if I wanted to follow suite and coat/paint my pipes? Any foreseeable downsides (chipping, flaking, etc..)?

If anybody knows a good shop in/near Minneapolis... I take recommendations.



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post #36 of 53 Old 09-01-2010, 06:51 PM Thread Starter
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Hey how do you find those turn signals - are they bright in the daylight? - some brands are not very clear in the day time. Thanks.
They work great - I think they are 3 Watt LED's so they are bright enough.

Nobody has hit me yet, so I guess that counts for something! *knock* wood

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2006 Honda 599 - Ex wrecked it :-D
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post #37 of 53 Old 09-01-2010, 07:03 PM Thread Starter
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Quote:
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I know it's tacky to ask about money... but I LOVE those ceramic coated/painted pipes. My header looks like crap, so I am thinking this might make a good winter project.

So how much am I looking at if I wanted to follow suite and coat/paint my pipes? Any foreseeable downsides (chipping, flaking, etc..)?

If anybody knows a good shop in/near Minneapolis... I take recommendations.
The place I mentioned above quoted me $150 to coat the pipes. He sandblasted them first and coated both the outside and the inside. He also welded my two brackets for me and painted my can brackets. There was also a small hole in my headers that he didn't see, so he lost some of his ceramic liquid just doing my set of pipes. For all his trouble and extra work, I paid him $180. I hope it was enough for his work, he did an excellent job.

Powdercoat is definitely cheaper, I paid $170 for 35lbs of parts, (essentially all you see on the bike that is powdercoated).

The coating is definitely more fragile than you would think, much more so than powdercoat. It's made to take heat, not abrasion. I had to take my wedding ring off to install them, as just turning the pipes in my hand and rubbing against my ring left marks. Permanent marks. You can see three little nicks in the pipes near the midpipe. Those were just from installation, and I was really careful. So, I'm sure I'll have nicks and dings from rocks, road grime, etc. but when they get real bad, I'll probably yank them off and take them back to this guy and have them redone. They look really good.

I should have mentioned, I did clean off the end of the headers where they meet the engine, as well as the fittings in between each piece. The coating on both pieces was enough to make it really difficult to get them connected again. I just used my dremel tool and a small wire wheel.

2009 Aprilia Tuono - Ginger
2001 XR650R BRP (Big Red Pig)
2006 Honda 599 - Ex wrecked it :-D
2007 Honda CB900F (sold)
2006 Honda VTX 1300C (sold)
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post #38 of 53 Old 10-06-2010, 07:42 AM
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Re-reply from wrong thread. oops/.

Hey googl3it,

The bike looks freaking amazing. I love that black powder-coated look. I'm about to get a bunch of parts from my bike powder coated as well. I'm pretty confident I can do most of the tear-down. The only parts that have me concerned are these. Do they hold up the engine or are they held up by it? did you have to drop the engine to get them off?

Any advice you can give?

Thanks

P.S. I asked this same question in a different thread that had a link to this one. My bad.
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post #39 of 53 Old 10-06-2010, 08:22 AM
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Quote:
Originally Posted by ekovach View Post
Hey googl3it,

The bike looks freaking amazing. I love that black powder-coated look. I'm about to get a bunch of parts from my bike powder coated as well. I'm pretty confident I can do most of the tear-down. The only parts that have me concerned are these. Do they hold up the engine or are they held up by it? did you have to drop the engine to get them off?

Any advice you can give?

Thanks

P.S. I asked this same question in a different thread that had a link to this one. My bad.
No need to drop the engine to take that bracket off. Under the small plastic cap is the bolt that holds the swing-arm.

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post #40 of 53 Old 10-06-2010, 08:34 AM Thread Starter
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Quote:
Originally Posted by rickard919 View Post
No need to drop the engine to take that bracket off. Under the small plastic cap is the bolt that holds the swing-arm.
+1. I actually have some videos we took of our bikes torn apart when we did this. Was actually really easy. And I don't even have stands, I just used some jack stands and a 12" piece of rebar through the center-stand holes.

I'll try and get them up sometime so you can see them.

2009 Aprilia Tuono - Ginger
2001 XR650R BRP (Big Red Pig)
2006 Honda 599 - Ex wrecked it :-D
2007 Honda CB900F (sold)
2006 Honda VTX 1300C (sold)
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