Set of R6 headers on the FZR400/600

[buzzawak]

My version of R6 headers on the FZR400/600. decided to retain the cross pipe between cylinders 2 & 3.
Still need to do the rear mount and may end-up raising the oil cooler a bit


Just took the bike for a run to test out the R6 headers. Most noticeable difference is how well it pulled after 8k and kept pulling hard right up to red line.
With the old header it would flatten out after 9K

[loganlexow]

How are you bending the tubes to fit? I have been incredibly curious about this but I can't wrap my head around the immense difficulty that is bending

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[SouthendChris]

I take yours is a 1WG FZR400 ????

What model/year R6 did the new headers come from ???

Very curios as I am looking at putting R6 headers on my 3TJ bike eventually.

Chris

[buzzawak]

My bike is a 1WG FZR400 frame with fzr600 engine, the headers are from a 2004 R6. Cost me $100 inc postage and were in great condition.
You can buy a set of modified R6 headers from "thatkid" for $130 US but because I live in Australia, the postage would have been more than the headers.

All I did was to cut the cross pipe between cylinders 2 and 3 then made up a jig (length of 1-1/2" square pipe) to hold the 4 pipes parallel.
Used a expanding screw thread between the pipe for cyl 2 and 3 to spread them while heating up the pipe just before the final join.
Once I got the right gap between cyl 2 & 3, welded in a piece of matching pipe to rejoin the cross pipe.
The gap between pipes 1 & 2 and 3&4 need to be increased also but its only about 3mm so I just forced them in-place when installing the headers on the bike.

One interesting thing I found is that the headers are zinc plated steel. Zinc can be polished to near chrome finish. This I did but you have to be careful as I would assume
the plating isn't that thick. I ended up putting on a clear flameproof coating just in-case I over did it with the polishing. I left a hidden section of the pipe uncoated and if it stayed
rust free I will end-up removing the clear coat.

Another thing to remember is that the R6 headers end about 2" shorter and a bit larger that the original headers so you need an extension pipe with one end reduced if you are going to use the original can.