Area P Installation Question

kevheads · January 6th, 2012, 09:40 PM

Mounting the header to the engine the 4 bolts don't match up perfect,if I squeezed the two pipes together a little by hand I can get all 4 bolts lined up and it slides on about half way,enough to get the nuts started but not enough that the bolts are completely through the nuts.It's still about 1/32"-1/16" from hitting the crush washers.Is this normal or should it seat down all the way by hand. I don't want to torque them the rest of the way and muck something up.

csmith12 · January 6th, 2012, 09:54 PM

No, should look like this;

They are not all the way inserted or something is blocking.

Kevin2109 · January 6th, 2012, 09:59 PM

It does take a little bit of moving around but both will sit flush if it was made correctly

EsrTek · January 7th, 2012, 05:22 AM

Mine would NOT sit flush, it seemed as if the casting was just a bit off. ( I almost returned my full system due to it ).
I too had a hard time just getting the bolts in the 4 holes, and when it did it was barely on them all.
I put the nuts on and proceeded to tighten all nuts equally until it was completely set.

00NissanNinja · January 7th, 2012, 06:51 PM

Quote:

Originally Posted by EsrTek

Mine would NOT sit flush, it seemed as if the casting was just a bit off. ( I almost returned my full system due to it ).
I too had a hard time just getting the bolts in the 4 holes, and when it did it was barely on them all.
I put the nuts on and proceeded to tighten all nuts equally until it was completely set.

I had that problem to. It was kind of pissing me off that it wouldn't line up on the studs. Eventually wiggled the thing on there, but tightening to their torque specs the left side of my exhaust has quite the gap (I tightened the exhaust down evenly). You can still see the washer and its crushed more at the top than at the bottom like so:

IMG_20111210_211458.jpg

I don't want to torque it up more and snap a stud of, but the way it looks seems like it might have a leak there at some point. I also still get a bit of popping on decel after removing the kleen system and exhaust leaks could be the cause. Do any of you remember what you may have torqued it to? or did you just tighten till it was mostly flush

kevheads · January 7th, 2012, 07:25 PM

Quote:

Originally Posted by 00NissanNinja

I had that problem to. It was kind of pissing me off that it wouldn't line up on the studs. Eventually wiggled the thing on there, but tightening to their torque specs the left side of my exhaust has quite the gap (I tightened the exhaust down evenly). You can still see the washer and its crushed more at the top than at the bottom like so:

Attachment 16575

I don't want to torque it up more and snap a stud of, but the way it looks seems like it might have a leak there at some point. I also still get a bit of popping on decel after removing the kleen system and exhaust leaks could be the cause. Do any of you remember what you may have torqued it to? or did you just tighten till it was mostly flush

I finally gave up on it, mine is the left side also, mine is off so much that the part of the pipe that the crush washer is on won't even start into the engine. You can see a 1/64" gap on the top. The right side goes in smooth till the left side hits. If I match it up to the OEM pipe, you can see that right side flange isn't straight with the left side compared to the OEM pipe.

00NissanNinja · January 7th, 2012, 07:45 PM

Quote:

Originally Posted by kevheads

I finally gave up on it, mine is the left side also, mine is off so much that the part of the pipe that the crush washer is on won't even start into the engine. You can see a 1/64" gap on the top. The right side goes in smooth till the left side hits. If I match it up to the OEM pipe, you can see that right side flange isn't straight with the left side compared to the OEM pipe.

Yep, sounds exactly like my header pipes as well. That sucks...

kevheads · January 7th, 2012, 08:21 PM

I was going to give them a call Monday morning.

EsrTek · January 8th, 2012, 05:25 AM

I checked mine several times now for leaks by headers, have not found one yet. I did continue to tighten mine past what I first thought was on. I counted the threads on the bolts and tried to get em all even amounts sticking out the nut.
Those crush washers they provide where the biggest PITA to keep on the header pipe anyway, I think I got mine crushed down good though.

Remember to re-seat all the bolts after first ride!

racegunnr · January 8th, 2012, 07:10 AM

once i took the collector pipe off(where the 2 go into 1) i could line up both pipes to fit nicely, do not tighten them down all the way, leave 'em loose enough to be able to wiggle them to get the collector pipe back on. I struggled for awhile befor i got them to fit square.

00NissanNinja · January 8th, 2012, 02:24 PM

^Race exhaust? I should have mentioned mine is the 18" quiet core and the entire pipe is one piece. I assume the OP has the non-race exhaust as well.

samw · January 8th, 2012, 03:40 PM

I'll be installing my Area P high mount race exhaust later this week... I sure hope I don't run into this issue

kevheads · January 8th, 2012, 06:01 PM

Quote:

Originally Posted by 00NissanNinja

^Race exhaust? I should have mentioned mine is the 18" quiet core and the entire pipe is one piece. I assume the OP has the non-race exhaust as well.

Yea, mines also the 18" Quiet Core.

racegunnr · January 8th, 2012, 08:26 PM

that would make a difference......

00NissanNinja · January 8th, 2012, 08:33 PM

Wellz, I guess I'll make a call about it too. I had pm'ed kbryant about it but he didn't say much about the fit of it; mainly just as long as there aren't any leaks its fine. The way it meets up with my head on the left side really doesn't look right (there could be a small leak but I can't tell with absolute certainty). Would have called sooner but I've been quite busy

Slono · January 23rd, 2012, 08:28 PM

Are there any updates regarding this issue? I'm only curious to see if this affects performance in any way.

kevheads · January 23rd, 2012, 08:52 PM

Quote:

Originally Posted by Slono

Are there any updates regarding this issue? I'm only curious to see if this affects performance in any way.

After talking with Kerry, I sent the pipe back to him, he e-mailed me when he got it and said he could see why it didn't fit and sent me another one, I got it last week and it went right on with no problems. Great customer service.

(Affecting performance)- bike is winterized,still sitting inside my sunroom. Haven't started it up yet.

Slono · January 23rd, 2012, 08:55 PM

Great, thanks!

00NissanNinja · January 24th, 2012, 12:10 AM

Quote:

Originally Posted by Slono

Are there any updates regarding this issue? I'm only curious to see if this affects performance in any way.

Mines is okay, I had it checked for leaks. I talked to Kerry and he said if any issues occur to just call him up and they will take care of it.

January 6th, 2012, 09:40 PM	#1
kevheads ninjette.org guru Name: Kevin Location: central Illinois Join Date: Apr 2011 Motorcycle(s): 2011 Green 250R Posts: 346	Area P Installation Question Mounting the header to the engine the 4 bolts don't match up perfect,if I squeezed the two pipes together a little by hand I can get all 4 bolts lined up and it slides on about half way,enough to get the nuts started but not enough that the bolts are completely through the nuts.It's still about 1/32"-1/16" from hitting the crush washers.Is this normal or should it seat down all the way by hand. I don't want to torque them the rest of the way and muck something up.

January 6th, 2012, 09:54 PM	#2
csmith12 The Corner Whisperer Name: Chris (aka Reactor) Location: Northern KY Join Date: May 2011 Motorcycle(s): 2010 250 (track), 1992 250, 2006 R6 (street/track), 2008 R6 (track) Posts: Too much. MOTY 2015, MOTM - Nov '12, Nov '13	No, should look like this; They are not all the way inserted or something is blocking. __________________________________________________ Goal: Shake A Million Hands \| Look through the corners \| Track Day Prep \| Closest track? \| The Mid-Ohio School

January 6th, 2012, 09:59 PM	#3
Kevin2109 KThanksBye Name: Kevin Location: Orange County Join Date: Mar 2011 Motorcycle(s): 2006 zx636r Posts: A lot.	It does take a little bit of moving around but both will sit flush if it was made correctly __________________________________________________ ----> My Youtube! <---- Unregistered, watch my youtube page!

January 8th, 2012, 02:24 PM	#11
00NissanNinja I hate driving... Name: S Location: SW Ohio Join Date: Jul 2010 Motorcycle(s): 13 Triumph Street Triple R, 09 Ninja 250r (Sold 4/20/12) Posts: A lot.	^Race exhaust? I should have mentioned mine is the 18" quiet core and the entire pipe is one piece. I assume the OP has the non-race exhaust as well. __________________________________________________ 09 ninja 2fiddy SE Driving slow things fast

January 8th, 2012, 08:33 PM	#15
00NissanNinja I hate driving... Name: S Location: SW Ohio Join Date: Jul 2010 Motorcycle(s): 13 Triumph Street Triple R, 09 Ninja 250r (Sold 4/20/12) Posts: A lot.	Wellz, I guess I'll make a call about it too. I had pm'ed kbryant about it but he didn't say much about the fit of it; mainly just as long as there aren't any leaks its fine. The way it meets up with my head on the left side really doesn't look right (there could be a small leak but I can't tell with absolute certainty). Would have called sooner but I've been quite busy __________________________________________________ 09 ninja 2fiddy SE Driving slow things fast

January 7th, 2012, 05:22 AM	#4
EsrTek ninjette.org certified postwhore Name: Eric Location: Murfreesboro, TN Join Date: Jun 2011 Motorcycle(s): '13 300 Posts: A lot.	Mine would NOT sit flush, it seemed as if the casting was just a bit off. ( I almost returned my full system due to it ). I too had a hard time just getting the bolts in the 4 holes, and when it did it was barely on them all. I put the nuts on and proceeded to tighten all nuts equally until it was completely set.

January 7th, 2012, 08:21 PM	#8
kevheads ninjette.org guru Name: Kevin Location: central Illinois Join Date: Apr 2011 Motorcycle(s): 2011 Green 250R Posts: 346	I was going to give them a call Monday morning.

January 8th, 2012, 05:25 AM	#9
EsrTek ninjette.org certified postwhore Name: Eric Location: Murfreesboro, TN Join Date: Jun 2011 Motorcycle(s): '13 300 Posts: A lot.	I checked mine several times now for leaks by headers, have not found one yet. I did continue to tighten mine past what I first thought was on. I counted the threads on the bolts and tried to get em all even amounts sticking out the nut. Those crush washers they provide where the biggest PITA to keep on the header pipe anyway, I think I got mine crushed down good though. Remember to re-seat all the bolts after first ride!

January 8th, 2012, 07:10 AM	#10
racegunnr ninjette.org member Name: shane Location: south dakota Join Date: Nov 2011 Motorcycle(s): 09 250r race bike, 06 R6 race bike, 06 YZ450f Tard Posts: 122	once i took the collector pipe off(where the 2 go into 1) i could line up both pipes to fit nicely, do not tighten them down all the way, leave 'em loose enough to be able to wiggle them to get the collector pipe back on. I struggled for awhile befor i got them to fit square.

January 8th, 2012, 03:40 PM	#12
samw ninjette.org member Name: Sam Location: Ohio Join Date: Nov 2011 Motorcycle(s): 2005 HON CBR1000RR Repsol, 2012 KAW Ninja 250R Posts: 131	I'll be installing my Area P high mount race exhaust later this week... I sure hope I don't run into this issue

January 8th, 2012, 08:26 PM	#14
racegunnr ninjette.org member Name: shane Location: south dakota Join Date: Nov 2011 Motorcycle(s): 09 250r race bike, 06 R6 race bike, 06 YZ450f Tard Posts: 122	that would make a difference......

January 23rd, 2012, 08:28 PM	#16
Slono ninjette.org guru Name: Solon Location: Toronto, Ontario Join Date: Jun 2011 Motorcycle(s): 2011 Kawasaki Ninja 250R (sold), 2007 SV650s (deer wrecked), 2010 Suzuki SV650S Posts: 334	Are there any updates regarding this issue? I'm only curious to see if this affects performance in any way.

January 23rd, 2012, 08:55 PM	#18
Slono ninjette.org guru Name: Solon Location: Toronto, Ontario Join Date: Jun 2011 Motorcycle(s): 2011 Kawasaki Ninja 250R (sold), 2007 SV650s (deer wrecked), 2010 Suzuki SV650S Posts: 334	Great, thanks!

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