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Will try to take some completed pics tonight. Didn't feel like it last night, was watching TV, drinking beer, and working on the bike......
So I swapped the 2006 Kat 600 Oil Pan and pickup onto my 91 600.
I ended up ordering new bolts (cheap insurance). Now I don't know if post 98 Kat's already come with regular hex head bolts on the oil pan, but the factory bolts on my 91 600 were allen head. The replacment bolts were M6 hex heads....and these were Suzuki bolts. If you want to replace bolts, save some time and go to the Hardware store. Lowe's had some M6 bolts for around .50 each. They had the correct lengths as well.
The pre-600 pickup you have to take the screen off to get to the 2nd bolt. I don't think that would have been such an issue, if I hadn't of been drinking at the same time. LOL
The 98+ pickup has two bolts on the outside. It's a straight bolt in.
For those who dented the collector on a 98+ header to clear a pre-98 oil pan...what did you do? Run the header over with a truck? Would have taken me longer to dent the thing than swap pans.
The exhaust bolts for 98+ are a tad longer. Again hit the hardware store. Exhaust bolts are M8 1.50 not 1.0.
Pre 98 header = 35mm
98+ header = 25mm
The flangers on the headers make the difference.
After installing the pan, replacing the oil filter and adding the filter magnet (thanks CP) got the header bolted up and installed the new-to-me Scorpion slip-on. As I tried to figure out a way to hang the can, I looked at the insulated pipe hangar that someone on here used...but I wanted to use the stock mount / hole location where the pre-600 exhaust originally bolted up...ended up using some 3/4" galvanized strapping. Looks pretty good, I think I'll work on bending up a piece of stainless. But it's solid and works well.
Sound is WICKED!!!! Not too loud, not too quiet. Sounds great about 8K RPM!!! My son says it "Really sounds like a motorcycle now......"
I know it's all in my head, but throttle response at lower RPM's seemed better.
Also nice to be able to see / clean / adjust my chain without dealing with the LH muffler.
When installing the Fumoto valve, as CP has noted, you have to grind the ridge down on the 98+ pan to be able to tighten the Fumoto and get to the Valve. Dremel + cut off wheel then some smoothing worked okay.
As for trimming the belly pan....one of the tubes (I'll say tube #3 from memory) does slightly hit. But the heat from the pipe nicely clearanced itself and it looks factory LOL.....not hacked.
NOTE TO SELF: When warming the bike up after installing anti-seize on the header bolts.....write yourself a note so you don't start wondering where the heck all the smoke is coming from.
I also went to the synthetic 5W-40 Rotella from 15W-40 dino Rotella. We'll see how it goes, but the bike actually seemed to warm up faster.......again could be in my head.
I've got a Bandit 1200 rear shock on the way, and with the addition of some longer spacers in the front forks, I think the suspension will be much happier, especially riding two up.
Total Cost was pretty cheap...guess I got lucky:
- Used Scorpion Slip-on in perfect shape $100
- 98+ oil pan and pickup $20
- Bolts , strapping, muffler connector etc $30
Chris
So I swapped the 2006 Kat 600 Oil Pan and pickup onto my 91 600.
I ended up ordering new bolts (cheap insurance). Now I don't know if post 98 Kat's already come with regular hex head bolts on the oil pan, but the factory bolts on my 91 600 were allen head. The replacment bolts were M6 hex heads....and these were Suzuki bolts. If you want to replace bolts, save some time and go to the Hardware store. Lowe's had some M6 bolts for around .50 each. They had the correct lengths as well.
The pre-600 pickup you have to take the screen off to get to the 2nd bolt. I don't think that would have been such an issue, if I hadn't of been drinking at the same time. LOL
The 98+ pickup has two bolts on the outside. It's a straight bolt in.
For those who dented the collector on a 98+ header to clear a pre-98 oil pan...what did you do? Run the header over with a truck? Would have taken me longer to dent the thing than swap pans.
The exhaust bolts for 98+ are a tad longer. Again hit the hardware store. Exhaust bolts are M8 1.50 not 1.0.
Pre 98 header = 35mm
98+ header = 25mm
The flangers on the headers make the difference.
After installing the pan, replacing the oil filter and adding the filter magnet (thanks CP) got the header bolted up and installed the new-to-me Scorpion slip-on. As I tried to figure out a way to hang the can, I looked at the insulated pipe hangar that someone on here used...but I wanted to use the stock mount / hole location where the pre-600 exhaust originally bolted up...ended up using some 3/4" galvanized strapping. Looks pretty good, I think I'll work on bending up a piece of stainless. But it's solid and works well.
Sound is WICKED!!!! Not too loud, not too quiet. Sounds great about 8K RPM!!! My son says it "Really sounds like a motorcycle now......"
I know it's all in my head, but throttle response at lower RPM's seemed better.
Also nice to be able to see / clean / adjust my chain without dealing with the LH muffler.
When installing the Fumoto valve, as CP has noted, you have to grind the ridge down on the 98+ pan to be able to tighten the Fumoto and get to the Valve. Dremel + cut off wheel then some smoothing worked okay.
As for trimming the belly pan....one of the tubes (I'll say tube #3 from memory) does slightly hit. But the heat from the pipe nicely clearanced itself and it looks factory LOL.....not hacked.
NOTE TO SELF: When warming the bike up after installing anti-seize on the header bolts.....write yourself a note so you don't start wondering where the heck all the smoke is coming from.
I also went to the synthetic 5W-40 Rotella from 15W-40 dino Rotella. We'll see how it goes, but the bike actually seemed to warm up faster.......again could be in my head.
I've got a Bandit 1200 rear shock on the way, and with the addition of some longer spacers in the front forks, I think the suspension will be much happier, especially riding two up.
Total Cost was pretty cheap...guess I got lucky:
- Used Scorpion Slip-on in perfect shape $100
- 98+ oil pan and pickup $20
- Bolts , strapping, muffler connector etc $30
Chris
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