How to Install a Full Motorcycle Exhaust System + Best Header and Silencer Combo for Kawasaki Z900

[@motomaddox]

Update: Added the Brock’s Performance Stage 1 ECU Tune - kzbin.info/www/bejne/enjEqml9jtOFotE

[@stonehouseguitars3869]

Bro you've got the most calm relaxed voice and attitude I've ever seen lol. Thanks for the video 👍🏻 installing headers on my 900 next week

[@motomaddox]

Appreciate the compliment! You're going to enjoy the results after your install.

[@stonehouseguitars3869]

@@motomaddox I went with the m4 headers because everything else I could find was on backorder for like 2 months. Hopefully they're decent and a good fit. Gonna pair it with SC Project CRT can. Just wanted to see generally what it was like to do on this bike. Looks basically the same as other bikes Ive done it on though so that's good. Only thing I'm worried about is the tight clearance around the headers.

[@motomaddox]

@@stonehouseguitars3869 m4+sc project should be nice. All you have to do is be patient when dry fiting the pipes to make sure everything is clear before tightening fully.

[@stonehouseguitars3869]

@@motomaddox thanks for the advice brother

[@awong2912]

How do you get to the header pipe bolts with the radiator in the way? Do you need some special tools/socket wrench?

[@Broken-six]

Trying to get the courage to tackle my header job! Need to get it done and flashed before our meetup! Going to get my new tires installed as soon as possible, get the whole project knocked out!

[@motomaddox]

That ZX10R is a beast!

[@oswaldorodriguez5416]

Hey great video I’m going to do black widow headers combo with a Leo Vince slip on. What kind of sealer did you use for the header gasket?

[@motomaddox]

I didn't need to use sealer for the header pipe connections to the engine. The kit comes with replacement crush gaskets that you just swap out the OEM ones for. The sealer is only for the pipe connections down stream. Thanks for the compliment on the vid!

[@clubstyleridahd4695]

Are the header pipes coming directly out of the motor tappered or stepped up from a smaller piper to larger like the akropavic does? Love your exhaust set up btw!

[@motomaddox]

Thanks for the compliment! I just ran out to my garage and looked at the OEM header pipes that I kept. The OEM inlet pipes that actually mate to the exhaust ports from the motor have a small 15mm section of the pipe that has an OD=41mm and ID=32.5mm After that initial length of 15mm pipe, the OD of the pipe tapers down to 35mm. The aftermarket Black Widow UK set that I have on now has an OD=38mm. So the OEM pipes do have more restricted flow than the replacement set I have installed. Hope this helps.

[@yyvg0ddx137]

Hey man this video helped me a lot but I got one problem :/ the headers always seem that doesn’t fit well on the engine, even if I pull all my power on the keys, the headers moves quite a bit and I feel air when I turn on the engine coming from the headers, any advice? Sorry for bad English tho

[@motomaddox]

Hey I missed this comment. Did you ever figure out the problem? I know I had to take extra care to make sure I removed the original header gaskets/washers and replace them with the new crush washers that came with the new kit. I also just hand tightened the bolts until I felt the pipes where aligned well. I can't recall exactly what order I tightened the bolts, but I believe I worked from the inside out, being careful to tighten each one a little at a time to minimize uneven pressures one one side or another.

[@yyvg0ddx137]

@@motomaddox hey man, yea the original has a different size than the black widow gaskets, that’s why it wasn’t working well, everything’s fine now! Thanks for the vid and the attention!

[@EugenioLiso-fj4bt]

Buddy the diameter of the headers are bigger then the original or not?I want to buy aswell.greating from Edinburgh

[@motomaddox]

Yes. The diameter of the black widow headers are LARGER than stock/original.

[@EugenioLiso-fj4bt]

Great did you remap ?

[@stonehouseguitars3869]

So I got the rest of it off and im trying to drop the headers. Whats the best way to get at those header bolts? Did you remove the radiator? - edit nevermind im an idiot just needed longer extension lols

[@motomaddox]

How did the install work out for you? Hope you're enjoying the new sound!

[@santaellal]

Excellent video, I'm waiting for mine, currently I only have Leovince slip-on with your video, I'm going to try to put it together myself. Greetings from Chile.

[@motomaddox]

Your going to really enjoy the end result after it's all put together! Thanks for the comment.

[@lumpvision5746]

Thanks for the video. Did the headers come with instructions? I don't think I saw you look at instructions while putting the pipes together before installation.

[@motomaddox]

There were some really general instructions included in the packaging. Things like "remove OEM system" and "install new system". KZbin videos are a good source for the details. You just have to be really patient with the alignment before tightening things up to make sure the pipes aren't too close to other parts of the bike.

[@lumpvision5746]

@@motomaddox wow! That's odd that there's no legit instructions! Oh well! Thanks for responding so quickly.

[@EugenioLiso-fj4bt]

Buddy I have got black widows headers but the original gaskets doesn’t fit perfect when I m gonna install the pipe.i need to use only the gaskets which black widows supply me?

[@motomaddox]

Yes, you need to remove the original gaskets and install the new crush washers that came with the new system.

[@Softverasuhardveru]

Hello, did you do any tuning of the ecu after this install? Any check engine lights or anything?

[@motomaddox]

No, I did not get the ECU flashed. I plugged the original O2 sensor in to the new system and haven't had any warning lights or issues. Some of these systems do not require an ECU tune at all, as long as you hook the O2 sensor back up.

[@motomaddox]

Update: Added the Brock’s Performance Stage 1 ECU Tune - kzbin.info/www/bejne/enjEqml9jtOFotE

[@awong2912]

How do you get to the header pipe bolts with the radiator in the way? Do you need some special tools/socket wrench?

[@motomaddox]

There is enough space to access the header bolts with deep sockets and extensions.

[@thynard]

Hi I have a 2022 z900 performance :) what’s the torque setting on the header nuts?

[@motomaddox]

Per the Z900forum.com site, a resource that I frequent, I've seen 20Nm (15ft-lbs). Hope that helps!

[@pmudri]

Hey, great video. I'm waiting for the same headers to arrive. Question: do I have to do a remap after installing it or software takes care of everything on its own?

[@motomaddox]

Thanks for the compliment and for checking out the vid. These headers have a spot for the O2 sensor, so there is no requirement to remap the ECU as long as you keep the sensor connected/active. I don't have any issues or warning lights with the new setup.

[@pmudri]

​@@motomaddoxI managed to mount them but I have an air "leak" up in the front, where headers connect to the engine and its making a sound. Would you recommend using sealant?

[@motomaddox]

@@pmudri Did you remove the original/oem header gaskets/washers and replace them with a new set that came with your headers? That is the only thing I can think that may be your issue. Whatever the problem is, DO NOT use any pipe or exhaust sealant at the headers. It will only make a mess and create an uneven and temporary seal. The headers interface just needs the right washers/ gaskets and adequate tourque on the fasteners.

[@motomaddox]

Update: Added the Brock’s Performance Stage 1 ECU Tune - kzbin.info/www/bejne/enjEqml9jtOFotE

[@EugenioLiso-fj4bt]

⁠@@motomaddoxbuddy you meet to remap because the bike run too lean now.thats why pops a lots .you won’t have performance and smoothness if you don’t remap

[@cybercrime535]

headers are titanum or stainless steel

[@motomaddox]

The headers are stainless.

[@vinaynair2054]

I have the same downpipes, i replaced the kawi engine gaskets to the BW rings but i am still having leaks from the engine manifold downpipes. With loud decel pops. How do completely seal the downpipes? Any idea?

[@motomaddox]

If you removed the original gaskets and replaced them with brand new crush washers, you should be able to get a good seal as long as the bolts are tightened properly. Regarding the deceleration pops, those are harmless. But if you want to get rid of the noise, you can block off the AIS/PAIR valvle.

[@vinaynair2054]

Hey, i did tighten the bolts completely but it still leaks a lot, should i try replacing the black widow gaskets with kawi gaskets?? please help i am out of solutions ​@@motomaddox

[@motomaddox]

@@vinaynair2054 I'm not sure if new Kawi OEM gaskets will work as they may have a different inner diameter than the black widow ones. You may have to confirm, because if they are different sizes, you may need to just get another fresh set from black widow. You did remove the kawi ones right? Sorry to hear you're having so much trouble with this.

[@vinaynair2054]

@@motomaddox hey i did remove the existing kawi gasket rings then installed these, in the black widow manual it was written to replace the oem gaskets only if damaged. So i think it shouldnt be a issue right?

[@motomaddox]

@@vinaynair2054 It's worth a try. Keep us posted!

[@dw0095]

I skipped the installation paste and noticed some carbon leaking out from the downpipes to the midpipe slip joints. Going to be tearing it apart and trying the paste. Did you use it?

[@motomaddox]

Yes, I used the paste with my Z900 and my Ninja 650 before that, and haven't had any problems.

[@dw0095]

​@@motomaddoxwell today I did a reinstall and added paste. Ordered new kawasaki copper header gasket rings and discovered that they were too thin. Had to reuse the silver thick black widow ones again. Couldn't get the headers tight with the kawasaki copper gaskets 🤷 nut was fully tight and headers still wiggled

[@motomaddox]

@@dw0095 Yeah the replacement gaskets that come with the BW headers are larger crush washers. I know it's been a pain to get it right, but I'm sure you're enjoying the sound!

[@Ktimerrr]

Where did. you get your Seat from? Why u do it smaller?

[@motomaddox]

The seat I have now is a custom seat from Corbin: kzbin.info/www/bejne/d3i1Z6yXnbeXbtE ...and that is a video I made showing how the new Corbin seat compares to the stock seat. The new seat has a slightly lower profile due to how it is contoured, but it actually is a bit wider and provides way more comfort and support over the stock seat. This new seat also doesn't push you forward into the tank like the OEM seat. This has been one of my most practical upgrades to date.

[@YuvrajSingha-wy7eo]

Where did you got that seat brother ?

[@motomaddox]

That's a Corbin seat. They do all types of custom color/material combinations. Checkout my video here where I talk about this exact seat upgrade: m.kzbin.info/www/bejne/d3i1Z6yXnbeXbtE

[@ElytraYT]

white z900??

[@motomaddox]

Yep. It's a sweet colorway!

[@Rickmac22]

Did you have to remove the radiator?

[@motomaddox]

I did not have to remove the radiator. You just need the right sockets and extensions to access the header bolts.

[@Rickmac22]

@@motomaddox Thanks man! Great video and keep posting ‘em!

[@motomaddox]

@@Rickmac22 You bet. Thanks for the support!