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Kz1000 header 22 Jul 2021 17:30 #852301

  • Mr. E
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I have a mystery header that I believe to be a Mac. My issue is the flanges on the headers are captured and non removeable but go so far down the stud that I couldn't put a nut on tight if I wanted.

I can see from the corrosion on the headers some sort of spacer was once used?

Suggestions?
1981 KZ750 Chopper, 1975 KZ400 , 1984 GPZ750 track build , 1977 kz1000, 1981 kz1000
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Kz1000 header 22 Jul 2021 17:56 #852304

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I can't really picture what might have been there before, but it seems like a stack of plain washers on each stud would take up the gap.
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'95 GPZ1100 (sold) , '00 ZRX1100
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Kz1000 header 22 Jul 2021 17:58 #852305

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Exhaust gaskets installed in the head?

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Kz1000 header 22 Jul 2021 18:00 #852306

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Not the best fix but you could double up the gaskets and add ultra copper between them. I like DOHC’s suggestion also. 
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
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Kz1000 header 22 Jul 2021 20:18 #852315

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Exhaust gaskets are installed. Making small sleeves/spacers was what I was considering but thought there must have been a better way haha. 2pc collars overt the top of something.
1981 KZ750 Chopper, 1975 KZ400 , 1984 GPZ750 track build , 1977 kz1000, 1981 kz1000

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Kz1000 header 23 Jul 2021 05:49 #852336

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My local hardware store has an assortment of steel and aluminum spacers that you can buy.  They come in different widths and diameters so you might find something that will work and look good too without going thru the chore of making them or stacking washers.

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Rick H.

1977 Kawasaki KZ-1000A1

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Kz1000 header 23 Jul 2021 07:42 #852344

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Suitable sized studs?   
Don't be ridiculous! It's only a flesh wound!

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Wife's BIG bike...... 1981 GPZ 1100 Kerker and factory FI Mikuni RS34s W/ K&N pods

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Kz1000 header 23 Jul 2021 07:51 #852345

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The wear marks on the pipe make me think that there are some missing split collars.

Here is a discussion thread with pictures.

www.kzrider.com/forum/2-engine/593029-ex...tion?start=12#624929
1982 KZ1000 LTD parts donor
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Kz1000 header 23 Jul 2021 09:02 #852353

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The MAC I have, has the collars welded on. That's why the flange can't be removed.  So they can't be missing, otherwise the flange would come off.

It's strange indeed.  Maybe the header is from some other bike, like a Suzuki GS or something?  I thought I recall they have a similar cylinder spacing from the Kz.

The Kz1000 flange is indeed pretty deep.  Great Post by Patton: 
www.kzrider.com/forum/2-engine/517233-78...aust-question#517244

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Kz1000 header 23 Jul 2021 11:28 #852366

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From the pic you posted it would appear that the stock split collars and stock flange were placed outside the welded flange on the pipe to take up the space.  Shorter studs, a stack of washers or a tube of correct ID, OD and length would be the quickest fix if you do not have the stock split collars and stock flange. 
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Kz1000 header 23 Jul 2021 12:39 #852371

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The OP said the flanges are not welded, but are captured, so split collars should work just fine.

Maybe I am confusing myself with terminology. The flange I am referring to Kawasaki calls the exhaust pipe holder. It fits over the threaded studs and transfers the pressure from the nut to the pipe, via a sleeve welded onto the pipe.. However, in re-looking at the picture, if the pipe holder was as far out as the wear marks, the studs would be too short to reach it. Some pretty short split collars would be needed, or some spacers as discussed above.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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Kz1000 header 23 Jul 2021 20:03 #852403

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I believe these were for the earlier year kz1000s, possible changes to depth of exhaust pocket for J motors?

anyway. Here is the fix for now.
 
1981 KZ750 Chopper, 1975 KZ400 , 1984 GPZ750 track build , 1977 kz1000, 1981 kz1000
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