Issue between the 02 and 06 stock exhausts.

[brooder]

I'm trying to fit an 06 stock exhaust on my 02. Both are from a 600. The 06 seems to be a bit longer and I can't get the mounting points to line up. I want to try switching the headers to see if that will make a difference.

Here's the question: Will this make a difference? At ronayers.com I found that the 02 and 04 headers are different part numbers. So are the headers different or are they just changing part numbers to have fun with us?

[coolhandluke]

02 exhaust

8) I got a 02 header from Special and put it on my 03, no issues, everything fit.

[Built4Speeed]

i know this is old but i figured it was the best place to bring it up instead of making a new thread. I would like to put a two brother exhaust on my 04 kat, but two brothers only lists them up to 03. from what read, suzuki played with the demensions on the exhaust a little between 03-04. Exactly what all the changed, i dont know (other than the length, Im pretty sure they changed that.) My question is, what do i need to do to get a Two Brothers (preferably C5) slip on mounted?

[KansasKat]

The exhaust hanger on the 98-02 are about 1/2 - 3/4 inch shorter on the rear bolt than the 03-06. I found out trying to swap my stock 2005 can for a D&D on my buddies 98.

[Built4Speeed]

so do i just need like a metal adaptor for the rear bolt? Or do i need on for all three bolts?

[brooder]

I couldn't get either bolt to go through when putting the 06 on. So it looks like it's both.

[Court93kat]

Could you guys cut down the midpipe and get them to fit better??

[brooder]

Problem with that is that there is a flange that is tacked onto the midpipe. I have no way to retack it if I have to move it. There also isn't a lot of room to move it further up the midpipe. If I could get ride of that flange, I'm sure trimming the midpipe would make it fit.

[coolhandluke]

02 exhaust

8) I just took a look at the part #'s on the exhaust( headers and muff) from RonAyers micro. Seems 98-03 are the same, different #'s from 04, looks like a change. I've got some 02 750 headers coming for a 03 600. Bought some 02 600 headers from Keith a while back, used a D&D and stock set up with no issues on the 03. I dumped the D&D to loud, looking at a Yoshi. Right now I'm running a 02 600 header with stock 03 muffler and mid.

[KansasKat]

We ended up going to the hardware store and fabricating an extension for the rear hanger from a door slider. Works like a charm!!!!!!

[brooder]

I've got some metal I can fab up to make an extension. I'm just trying to find out if i can do it without. I'm going to get some anti-sieze this week and try swapping out the headers to see if that makes a difference. If not, I'll have the bracket on there by Sunday night.