FZRSupport: the FZROnline Archive

Hi im fitting new header pipes to my fzr 400 3tj1 what is the best way to fit the gaskets ive got squashed copper ones is that ok and far can i tighten them up

Those gaskets are like $4 for a set so I would just replace them if your new header didn't come with new gaskets. As far as mounting them just stuff them in there. Usually they will stay in place with out any trouble. If they don't stay in place then use a little dab (just a tiny it per gasket) of something like Permatex Ultra Copper to hold them in place.

Ok there in i got studs that were 40mm in length put them in ive tightened the so that you can just see the stud inside the nut i worried ill strip the thread or do i keep going until the gap between the colars and the head itself are closed ??

Try a tap with a rubber mallet also make sure you are supporting the pipes underneath so they run parallel to the sump. A block or two of wood should help.that way you are pushing them in at the correct angle and not fighting the weight of the pipes.

There in solid but the bracket hole after the valve does not alight with the one on the bike

When you tighten the nuts on the studs you should be able to feel when the pipe touches the copper ring, the effort to turn the spanner changes. After this you're crushing the copper ring / seal /gasket, you want to do all of the nuts up so they're like that then nip them up evenly.
Down the bottom you need to undo the mount bracket from the frame so it's slack then you can get the bolt into the down pipes, the middle of the downpipe sid of the bracket is rubber so it can move a bit. I put a washer on it then do up the two bolts a bit at a time.

You've used the Coppa Slip on the bolts and studs huh ???

What evil said! Mine needed a little persuasion and fiddling to get it to fit the hole.but they do go!

I had to get the studs in first the the bracket even a car jack was struggling to line the hole and bracket bolt up didnt want to put too much pressure on the header studs i didnt use copper grease due to too many different opinions i dont think theres no leaks as i cant smell fuems by the headers