2011-15 ZX-10R Header Retrofit?

[kman0066]

Someone else mentioned it on here before (but can't find the post) and so I've been trying to research it to see if the 2011 ZX-10R header will fit the H2 SX. The exhaust gaskets are the exact same from Kawasaki, so it would appear the ports are the same size and shape. I guess what's left is the port angle and general clearance. Has anyone looked further into this and can provide any more insight? I have a chance to pick up a very clean ZX-10R header, but since it's titanium I don't have the resources to weld on it and change it if it doesn't fit.

I know the exit is different, but I can weld up a link pipe no problem out of stainless. It's purely, will the header fit on the bike and I can take it from there.

[Rymek]

viewtopic.php?f=8&t=420

you meant this?

[kman0066]

No, not the slip-on, the other part of the exhaust.

[57x]

I will know today. I have my fairings off and am hoping to have it fitted this afternoon. It is hard to see inside, behind the radiator, but the port spacing appears to be a little different. Again, this is with my "calibrated" eye veneer. It does look like the Akra mid pipe will fit, I just don' know if it will clear the bags. I will update later today.

[kman0066]

Nice, looking forward to hearing your results on the header.

[57x]

Well, good news and some work to be done.

- The header portion of the 2015 ZX10R fits well behind the radiator and under the oil pan on the H2 SX, as well as the tubes lining up with the head without pulling/pushing on them.
- Unfortunately, the H2 SX flange at the top of the primary tubes is thicker than the ZX10R, so when you tighten up the clamp the header is still loose. Some split washer can fix this issue. If I get some made I will get a bunch of them made for others.
- The mid-pipe is a little too high at the rear to clear the bags. It does clear the center stand fortunately. A minor issue, but the mid pipe has to be tig welded after adjusting the angle if you use the Akrapovic titanium mid.

The stock exhaust is 31 lbs/14 KG for the header and can.
The ZX10R header, stainless mid that I used for mockup, and a titanium Muzzy can is 9.5 lbs/4.3 KG. This will be a little lighter with the Akra mid, but not a lot. The stainless mid is only 2lbs, so less than 1KG, so I will guess at 9lbs/4.1KG with the titanium Akrapovic.

How about an instant 22lb/9.9 KG diet for this bike, plus a bunch more power with a proper tune?????

More work to do.................

[kman0066]

Great news! When you're talking about the flanges and split washers, do you mean the nuts are just bottoming out and you need a spacer between the flanges and the nuts? Or is there a bigger problem?

[57x]

There needs to be a spacer between the header flange and the clamp

H2 SX header flange


2015 ZX10R header flange


Split washer to put between ZX10R flange and the clamp, 5mm thick.

[57x]

Here is the full system on the bike, but the bags are pushing the exhaust down, so it needs to be lowered a few degrees after the center stand.

[kman0066]

Ahh, got it. Easy enough fix. Bought my header, $65 for a Titanium header, like new condition. Heck yeah! Might take some custom work, but compared to a $2k aftermarket header, can't pass that up.