Those with Area P exhaust

LoD575 · July 10th, 2012, 07:44 PM

My Area P exhaust arrived today but it's causing me some problems during dry fitment.

I can not get the midpipe to dry fit into the exhaust ports. Exhaust flanges and all studs line up but the tubing of the left tube does not line up with the port causing scoring on the block. The midpipe is bottomed out against the frame leaving no vertical movement during fitment.

Here are some pics as well to further explain.

I shot an email off to Area p already to see what Kerry says.

Jiggles · July 10th, 2012, 07:51 PM

Hmm not sure, mine did take a bit of wiggling to get it on there though

LoD575 · July 10th, 2012, 07:58 PM

I figured it would be tight but not score the block like it is. Seems like a bend is slightly off.

EsrTek · July 10th, 2012, 08:06 PM

Seems to be a common theme w the Area P's. Mine was hard to fit also... had to do quite a bit of wiggling while tightening 1 bolt at a time, alternating bolts to not get too much pressure on 1 side.

Checked it several times for weeks after install to verify no leaks.

greg737 · July 10th, 2012, 09:53 PM

When you say "dry" fitment, what exactly do you mean?

That hard-as-all-hell stainless steel exhaust pipe should never come in contact with the soft aluminum alloy of the engine's head. There should always be a soft, easily deformed and protective copper gasket between the two. Right? Right?

According to the Area P "Kawasaki Ninja 250R Full System" product page:

Quote:

As of 12/15/2010 - All systems now include Area P custom exhaust port gaskets at no extra charge. Area P designed gaskets feature additional "crush volume" for superior sealing.

So the question is, why are you "dry fitting" the pipe without the exhaust port gaskets?

LoD575 · July 10th, 2012, 10:05 PM

Quote:

Originally Posted by greg737

When you say "dry" fitment, what exactly do you mean?

That hard-as-all-hell stainless steel exhaust pipe should never come in contact with the soft aluminum alloy of the engine's head. There should always be a soft, easily deformed and protective copper gasket between the two. Right? Right?

A nice fresh new set of exhaust gaskets, ordered from a Kawasaki parts supplier. Because you'd never think of using the old ones over again.

By dry fitment I mean before tightening everything up. The supplied Area P gaskets are in place but do not make any kind of contact with the mating surface.

The stainless exhaust tube is impacting the head causing deformation at the port. The semi circle indentation as seen in the pics is from the exhaust tube.

greg737 · July 10th, 2012, 10:16 PM

That is surprising to hear. In that case your best move is definitely to talk to Kerry.

I have an Area P, but my bike is a pre-gen. It installed easily.

Do you think it could be the gaskets that are the problem? Maybe Area P accidentally gave you the wrong size gaskets (meant for a different bike with a larger diameter exhaust tube)?

LoD575 · July 10th, 2012, 11:00 PM

Quote:

Originally Posted by greg737

That is surprising to hear. In that case your best move is definitely to talk to Kerry.

I have an Area P, but my bike is a pre-gen. It installed easily.

Do you think it could be the gaskets that are the problem? Maybe Area P accidentally gave you the wrong size gaskets (meant for a different bike with a larger diameter exhaust tube)?

I can't even get the pipe to sit remotely flush against the head. The exhaust tube is about 1/4" past the flange which should sit inside the exhaust port of the head. That little nub is the problem. The gasket doesn't even come into play yet.

I plan on holding off trying again until I hear from Kerry.

LoD575 · July 11th, 2012, 10:08 AM

Received an email this morning with a return shipping tag. Midpipe will go back for replacement.
Spoke with Kerry as well, he understood the problem and apologized for the issue. Excellent customer service and eager to resolve the situation.

LoD575 · July 17th, 2012, 04:41 PM

Update.

Kerry shipped out a new header pipe today. He checked the original pipe and found it was on the outer tolerance limits.

Kerry took care of the problem. He stands behind the product.

EsrTek · July 17th, 2012, 05:30 PM

Oh yeah Kerry is awesome.. I'm sure he would've replaced mine, but I got it on finally.

I really hope they do an exhaust for my next bike, as i love the sound it makes.

kevheads · July 17th, 2012, 06:57 PM

I had the exact same problem with my Area P i got in the last group buy.Kerry is great to work with. The second one he sent still took a little wiggling but it slid right in.

LoD575 · July 17th, 2012, 10:22 PM

I am really looking forward to installing this system and finish jetting.

I expect a tight fit of the system along the underside of the frame, that can be easily remedied.

This was a little too tight of tolerances with the flanges aligned.

LoD575 · July 25th, 2012, 09:44 AM

Update

Replacement header pipe arrived yesterday.

Pipe fit was tight as expected but no problems at all with the spigots and flanges. Solid system with excellent sound.

Now time to finish jetting.

sowega · July 25th, 2012, 09:47 AM

Kerry is a solid dude; not surprised to see such excellent service from him and the Area P team.

LoD575 · July 25th, 2012, 10:03 AM

Quote:

Originally Posted by sowega

Kerry is a solid dude; not surprised to see such excellent service from him and the Area P team.

Couldn't have said it any better.

July 10th, 2012, 07:44 PM	#1
LoD575 ninjette.org sage Name: Steve Location: Valdosta GA, US Join Date: Jul 2011 Motorcycle(s): 2012 Ninja 250, 2006 Ninja ZX6R-636 Posts: 661	Those with Area P exhaust My Area P exhaust arrived today but it's causing me some problems during dry fitment. I can not get the midpipe to dry fit into the exhaust ports. Exhaust flanges and all studs line up but the tubing of the left tube does not line up with the port causing scoring on the block. The midpipe is bottomed out against the frame leaving no vertical movement during fitment. Here are some pics as well to further explain. I shot an email off to Area p already to see what Kerry says.

July 10th, 2012, 07:51 PM	#2
Jiggles Jigglin' your Jiglets Name: Sean Location: San Jose, Ca Join Date: Jun 2011 Motorcycle(s): 2009 K1300S, 2013 Ninja 300, 2011 Ninja 250R, Faster than Unregistered's ninjette Posts: Too much. Blog Entries: 1 MOTM - Apr '13	Hmm not sure, mine did take a bit of wiggling to get it on there though __________________________________________________ If the Ninja 250 doesn't have enough power for you, then you don't know how to ride it. AFM #676 Supersports are for n00bs

July 25th, 2012, 09:47 AM	#15
sowega ninjette.org guru Name: Ed Location: Atlanta, GA Join Date: Mar 2011 Motorcycle(s): 899, 748, 250, 250, 70 Posts: 348	Kerry is a solid dude; not surprised to see such excellent service from him and the Area P team. __________________________________________________ Eberhart Creative

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
FS: Area-P solo exhaust bracket for Ninja 300 w/stock exhaust	c-dog	Motorcycle-related	2	September 12th, 2014 10:48 AM
Just got my Area P exhaust	staulkor	Videos	9	August 23rd, 2012 08:27 PM
area p exhaust	gsxrninja250	2008 - 2012 Ninja 250R Tech Talk	14	August 22nd, 2012 12:33 AM
Area P exhaust	Bosgarage57	1986 - 2007 Ninja 250R Tech Talk	16	August 22nd, 2012 12:15 AM
WTB: Area P full exhaust (or exchange 08+ stock exhaust)	mikecronis	Items Wanted	0	June 16th, 2010 05:54 AM

July 10th, 2012, 07:58 PM	#3
LoD575 ninjette.org sage Name: Steve Location: Valdosta GA, US Join Date: Jul 2011 Motorcycle(s): 2012 Ninja 250, 2006 Ninja ZX6R-636 Posts: 661	I figured it would be tight but not score the block like it is. Seems like a bend is slightly off.

July 10th, 2012, 08:06 PM	#4
EsrTek ninjette.org certified postwhore Name: Eric Location: Murfreesboro, TN Join Date: Jun 2011 Motorcycle(s): '13 300 Posts: A lot.	Seems to be a common theme w the Area P's. Mine was hard to fit also... had to do quite a bit of wiggling while tightening 1 bolt at a time, alternating bolts to not get too much pressure on 1 side. Checked it several times for weeks after install to verify no leaks.

July 10th, 2012, 10:16 PM	#7
greg737 - Name: - Location: - Join Date: May 2009 Motorcycle(s): - Posts: A lot.	That is surprising to hear. In that case your best move is definitely to talk to Kerry. I have an Area P, but my bike is a pre-gen. It installed easily. Do you think it could be the gaskets that are the problem? Maybe Area P accidentally gave you the wrong size gaskets (meant for a different bike with a larger diameter exhaust tube)?

July 11th, 2012, 10:08 AM	#9
LoD575 ninjette.org sage Name: Steve Location: Valdosta GA, US Join Date: Jul 2011 Motorcycle(s): 2012 Ninja 250, 2006 Ninja ZX6R-636 Posts: 661	Received an email this morning with a return shipping tag. Midpipe will go back for replacement. Spoke with Kerry as well, he understood the problem and apologized for the issue. Excellent customer service and eager to resolve the situation.

July 17th, 2012, 04:41 PM	#10
LoD575 ninjette.org sage Name: Steve Location: Valdosta GA, US Join Date: Jul 2011 Motorcycle(s): 2012 Ninja 250, 2006 Ninja ZX6R-636 Posts: 661	Update. Kerry shipped out a new header pipe today. He checked the original pipe and found it was on the outer tolerance limits. Kerry took care of the problem. He stands behind the product.

July 17th, 2012, 05:30 PM	#11
EsrTek ninjette.org certified postwhore Name: Eric Location: Murfreesboro, TN Join Date: Jun 2011 Motorcycle(s): '13 300 Posts: A lot.	Oh yeah Kerry is awesome.. I'm sure he would've replaced mine, but I got it on finally. I really hope they do an exhaust for my next bike, as i love the sound it makes.

July 17th, 2012, 06:57 PM	#12
kevheads ninjette.org guru Name: Kevin Location: central Illinois Join Date: Apr 2011 Motorcycle(s): 2011 Green 250R Posts: 346	I had the exact same problem with my Area P i got in the last group buy.Kerry is great to work with. The second one he sent still took a little wiggling but it slid right in.

July 17th, 2012, 10:22 PM	#13
LoD575 ninjette.org sage Name: Steve Location: Valdosta GA, US Join Date: Jul 2011 Motorcycle(s): 2012 Ninja 250, 2006 Ninja ZX6R-636 Posts: 661	I am really looking forward to installing this system and finish jetting. I expect a tight fit of the system along the underside of the frame, that can be easily remedied. This was a little too tight of tolerances with the flanges aligned.

July 25th, 2012, 09:44 AM	#14
LoD575 ninjette.org sage Name: Steve Location: Valdosta GA, US Join Date: Jul 2011 Motorcycle(s): 2012 Ninja 250, 2006 Ninja ZX6R-636 Posts: 661	Update Replacement header pipe arrived yesterday. Pipe fit was tight as expected but no problems at all with the spigots and flanges. Solid system with excellent sound. Now time to finish jetting.