yannih
Parking Attendant
Posts: 9
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posted November 08, 2012 05:03 AM
Yoshi Slip On Issue
Hi All,
Apologies if this has been raised elsewhere on this site but i am a newbie here.
Recently I ordered a set of 2008 Yoshimura Titanium/carbon R-77 Slip ons for my 2007 ZX-14. The well informed amongst you will recognize that Yoshimura do not make these for a 2007 but only for 2008 onwards which means the headers on the 2007 are at around 51mm and the mid pipes on the Yoshis are around 55mm! Hence a fitting issue!
Some may frown but I ordered these slip ons with this knowledge. The reason is I love the look of these pipes and will make them fit one way or the other.
But I thought I would throw it out there to the experts or anyone else who possibly has experienced and resolved this issue.
Does anyone have any advise or input on what the best way forward might be here. Sleeves, reducers, tape, etc?
Thankyou in advance for any assistance...
  
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GREYHOUNDMOSES
Expert Class
Posts: 324
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posted November 08, 2012 06:00 AM
Your dealer should be able to get the 2007 gaskets (marked A & B)
http://www.cornwallkawasaki.co.uk/shop/shop.php?cmd=showdiagram&id=13153
This should bring the diameter up to the later size.
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GREYHOUNDMOSES
Expert Class
Posts: 324
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posted November 08, 2012 06:03 AM
Just thinking. If you still have the OEM mufflers, the gaskets are probably still in the end under the clamps.
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yannih
Parking Attendant
Posts: 9
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posted November 08, 2012 12:28 PM
Thanks so much for you replies and diagrams.
But I am a little confused (which is not that surprising really...)
I haven't had the EOM mufflers off at this point as the Yoshis haven't arrived yet but are you saying the stock 2007 muffler mid pipes are to big and have the gasket in them to bring them down to the 2007 header size and that the current stock mid pipe size is a similar size to the 2008 Yoshi 's mid pipe and so using those gaskets already present should solve the issue?
It just seems a little unlikely as then the 2008 Yoshi pipes would fit a 2007 ZX-14 and they would just advise to use the gaskets already present in the OEM muffler assembly to make it fit.
Or have I just got your suggestion very wrong?
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yannih
Parking Attendant
Posts: 9
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posted November 08, 2012 01:45 PM
Greyhoundmoses, why did i ever doubt you???
I couldn't help myself and when downstairs to the garage and removed one of the stock mufflers for a look and low and behold, the gasket was there as you advised.
A great start but a slightly new challenge now.
Obviously the ID of the gasket is perfect for the 2007 header. But after some crude measuring the OD appears to be a little large at 60mm where the I believe the Yoshi mid pipe ID is 55mm.
So the gasket is a touch large in the OD department by approximately 5mm.
Can this gaskets OD be reduced and if so what would be the best way to achieve this? Will it compress to size with some effort?
Again any assistance would be greatly appreciated.
And thanks again for the great replies and support.
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dcjens
Pro
Wet side of Washington
Posts: 1059
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posted November 08, 2012 02:40 PM
Is your yoshi mid pipe sloppy in the hole or is the outside too big fir the header you have? Im confused. You can grind down the outside carefully. Somebody chime in with what gaskets are larger on the 07 08 or smaller? I have a similar prob with vance and hines and have an 06 and 07 header. I had a spare mid section that fit on the outside of the v&h midpipe and the nside of the stock lead gaskets to take up the space difference. Id rather get a thicker ID than shim crap. I thought about heating up some lead and filling in the space but thats lame
____________
Black 06
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yannih
Parking Attendant
Posts: 9
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posted November 25, 2012 07:22 AM
Thanks for the responses and help and all sorted now.
After much searching and frustration I finally found a muffler place that was willing to help (cause the guy was a rider himself and didn't knock me back like all the others simply because the requested help was for a motorbike and not a car) and made simple bushs/sleeves out of steel to take up the extra 3mm between the 51mm header and the 54mm mid pipe.
When i got them home the sleeves were acceptable OD's for the mid pipes but unfortunately still a little small ID for the headers so i dremelled a full length split along each sleeve and then fitted over the headers. This gave a 2 mm gap running lengthwise down the sleeves. This was filled with specific heat expanding muffler putty and the midpipes then were slid over for a perfect tight fit (with some effort needed to push them fully into place).
Everything is extremely solid and there are no leaks.
Very happy and now have Yoshimura R77 Titanium slip ons on my 2007 ZX-14 even though these pipes were only designed for 2008 models onwards.
Well worth the effort and initial frustration...
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yannih
Parking Attendant
Posts: 9
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posted November 25, 2012 07:25 AM
Forgot to add, its impossible to reduce the stock sleeves/bushes that come with the original header/pipes due to internal wire netting
in the construction process.
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