I just purchased an 08-12 slip-on to install on my 07 with stock header. I understand that the 07 header has a smaller OD and will require some type of gasketing to properly match up to the 08+ slip-ons. What has everyone used for this? Would it be fine just fabricating a thin stainless ring to slide over the header outlet?

http://www.bikebandit.com/houseofmotorcycles/2008-kawasaki-ninja-zx-14-zx1400c8fa/o/m148910#sch550635

for 40 bucks, it's not worth running around for some mickymouse setup. Match your header to the gasket year.

I'm not sure what material the OEM gaskets are made of but it's definitely not stainless steel. It's a soft material that feels very soft and is a bit flaky. Might be a lead alloy of some sort. But it is soft enough to fit over the header but then when you tighten the clamp, it gets squeezed into the shape between the two pipes and seals up tight.

I doubt that it's pure lead because the melting point of lead at about 320C is lower than what you might expect the gas to be on the backside of the catalytic converter. Typically that's at least 350-500C.

The gaskets are graphite. There is a 2mm difference between the '08 (53mm and '07 (51mm) header outlets to make up for the restriction of the third cat (added in '08). If you can make up the difference with some sleeves or collars, you can mak this swap work. You could possibly use both gaskets ('07 and '08) together, but that's just a guess on my part.

So... wouldn't the 08-12 header not fit on the 07 since Danno pointed out that the diameter is bigger?

Night, we have a muffler/header change that I tried already. Not too much fits between gens in the muffler to header category.

Header Gasket's inner and outer identification:

'06-07 = Same OD
'08-11 = Same OD

'06-07 = Diff ID
'08-11 = Diff ID

'06-11 All Mufflers = Same OD
'12-14 Mufflers = Diff OD

'06-11 - 1st Gen
'12-14 - 2nd Gen

Note the cat changed the ID but not the OD in the 1st Gen.
Note the bigger mufflers on the 2nd Gen is now mm's out of plugging in a smaller muffler.
Note all first gen mufflers fit any cat or non-cat header.
Note the cutoff as the OD changed between Gens.

I mentioned this before...but the Connie has a thinner gasket on it.Not as thick as the zx14's.You might try em.You'd need to buy two(if you have a dually that is)...the connie has a single outlet.

Go to youur local muffler shop and have them swedge the ID of the mid pipe to match the OD of the 07 header.

* Last updated by: EZX on 3/2/2014 @ 2:05 PM *

So... wouldn't the 08-12 header not fit on the 07 since Danno pointed out that the diameter is bigger?-Nightmare

The '08 header will fit the '07 engine and chassis, but the outlets and collector are bigger because of the 3rd cat. The '07 midpipe will not slip on over the '08 outlet.

Putting '08 slip-ons on an '07 header (original question) will require sleeving down the midpipe or sleeving up the outlets since there is a 2 mm difference.

The slip-ons I have fit with no graphite gasket, so if they are like that, adding the gasket may make up the difference.

* Last updated by: Danno on 3/3/2014 @ 5:20 AM *

Thanks for all of the input - I am going to try wrapping a bit of high temp flue tape or exhaust wrap around the header and really cranking down on the midpipe clamps

I should be getting the pipes in by this weekend and will let you all know how it works out

I ended up purchasing 2000'F thermal tape and wrapped the header outlets

http://www.amazon.com/gp/product/B000E283S0/ref=s9_simh_gw_p263_d0_i1?pf_rd_m=ATVPDKIKX0DER&pf_rd_s=center-5&pf_rd_r=0MH5Y5MAM0SHASSZ4P04&pf_rd_t=101&pf_rd_p=1688200422&pf_rd_i=507846

It seems to be holding up pretty well and I don't see signs of a leak. The pipes are pretty tight on there.

Engineering status, congratulations.

Excuse the last post, been reading Hubish too long.

Looks good. Years ago, aftermarket mufflers came with 2 or three different sleeves you could add or subtract to get the right diameter.