Katana 600 header installation
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  1. #1
    My Bike(s)
    Suzuki GSX600F

    Katana 600 header installation

    iv sucsessfuly removed all 8 bolts and the headers on my katana,
    iv bought new bolts and gaskets ready for when I put her back together again,
    but for the life of me it looks like the headers don’t have gaskets on when I removed them,
    and the new bolts seem a little tight ,
    have I got the wrong replacement kit?
    Or am I missing something?
    help and advice greatly appreciated

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  3. #2
    Seat Tester
    My Bike(s)
    2002 VS800
    Arizona Territory
    Not sure if you bought a single kit with new bolts & gaskets or if you bought bolts/gaskets seperately. You can compare the new bolts to the old ones, measure with calipers, you can sometimes even "mesh" the threads from old 'n new to see if the threads match like puzzle pieces which would indicate the same thread-pitch.

    Since you found no gaskets on the headers themselves, you might look more closely at the exhaust ports as it's not uncommon for carbon build-up to cover and kinda hide the old gaskets where they're seated in the exhaust ports.
    Riding Ain't A Hobby, It's A Lifestyle

  4. #3
    M-J Lifetime Achievement Award
    My Bike(s)
    Yamaha MT09
    Perth WA
    WHS^... plus check the old nuts on a random bolt then see if the new nuts will fit....they should be metric....from memory of most Jap bikes around 6 or 8mm. The pitch may be different in which case do not try and force them or you will stuff up the studs...far better to obtain the correct ones. Finally the threads may have carbon build up or corrosion a wire brush and a bit of WD40 may work wonders.

    Good luck
    Smoke me a kipper I'll be home in time for breakfast


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