Ok, so I gave up trying to swap the OEM header studs for new stainless ones and decided to just re-mount the down pipes.
Except now I've got another problem... 
The whole reason for my starting this was that the connection between the cat pipe and the one that leads from the headers, down underneath the engine was blowing, presumably because, when I had the new engine installed (see an old thread) the workshop didn't have the right gasket, so bodged it with exhaust bandage.
I've put the new gasket in, it's a very snug fit, but now I've to got try to get the headers into the sockets on the cylinder head and, at the same time, get the rear end into the bottom of the cat pipe.
Except I can't get them to line up!
The Haynes manual says do the header end first, then push the rear end into the cat pipe,  but when I put the headers in, the rear end is about half an inch out of place. probably because the tail end is about 2 inches deep.

I've looked at the idea of putting the cat end in first, but, because it's a very snug fit on the gasket, it won't go in easily and I don't want to just bash it into place with a rubber mallet because that will foc up the gasket.
So can anyone suggest what I can do to get this sorted...?

Hi everyone just joined the forum. After years of sportsbikes the time has come to admit I'm just getting too old for them now, my wrists, hips and knees are turning to cheese so I've decided to sell up and buy a fazer 1000.
I've done a bit research and these bikes sound perfect for me performance and comfort. I haven't bought my bike yet so if anyone has one coming up for sale around the £2200 mark give me a shout, cheers Choppa.

I deed to replace a little sound system and the one I am looking to buy has a Speaker power 20 W (10 W + 10 W)
But I already have speakers in position and I upgraded the wire to 42/0.15mm 3x6mm (whatever that is )My worry is using the in-situ speakers with the new system as I do not know what my current speakers power is. Looking down the back in an air hole thing I can see printed on the speaker I think it says 5W 8 ohlms but that is only on the small speaker as the bigger one has not got a hole. They are small at  20 x18x13
The online manual says this
Use the speakers only with the recommended system.If not, you can cause damage to the amplifier andspeakers and can cause a fire. Consult an approvedservice personnel if damage occurs or if there is a sudden apparent change in performance
The spec for the new system speakers is --- Speaker power 20 W (10 W + 10 W)So would it be ok to use the in situ speakers or would I actually get a better sound with the new spec speakers.I do not have any info on the old system. 

Great to see Scott Redding do the triple,he had to do the business in BSB after comments he made about it being a step to far down the ladder before signing for Paul Bird.When you come from Moto GP people think its going to be a walk in the park in a domestic series,it just goes to show you how competitive BSB really is,and what about Fores and Barbera? really on the pace,I thought this year was going to be a bit of a damp squib with everyone following the "works" ducatis but no way! cant wait for Brands. :woot

I've posted this on the FB group, but I thought I'd ask here too...

I'm having major hassles at the moment as I needed to replace the gasket at the bottom of the cat pipe on my FZ6 (2006) and decided I might as well replace the header bolts and studs since they were getting seriously manky.

Unfortunately, despite liberal spraying with Plusgas, tapping with a hammer and wedging two nuts together, I still can't get them to budge.

I went to B&Q and got myself a blow torch and some freeze spray, I've used more Plusgas, I've used the blow torch, I've used the freeze spray, but even with two nuts wedged together, the stud won't shift and I just end up unscrewing both nuts at the same time!

(And, yes, I cleaned the Plusgas off the stud before I put the nuts on!)

I've used a wire brush on a Dremel to clear as much rust off the base of the studs as I can and sprayed on more Plusgas, maybe they'll shift tomorrow...

Question: How long should I apply heat from the blowtorch? I've tried 30 seconds and then a minute, but I'm not sure how much effect it's having.
Anyone got any recommendations for how long I should use the torch without worrying about melting parts?

hi anyone got any dampers rods for the  front forks fzs600 fazer

For Sale. A set of Stainless Steel Downpipes. In very good condition, see attached photo's.


They definitely fit a Fazer  FZS600 Foxeye 2002 ( I removed them off my bike when I sold it, and refitted the standard downpipes).


I believe that they will fit all years of FZS 600 boxeye and foxeye 97-03. But please check for yourself first.


£100 inc postage to Mainland UK only.  Happy for you to collect in person if you prefer. ( Redcar / Teesside  area)

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Who wants my loctite 620. I brought a 50ml bottle for the front sprocket and probably will not have use for it again, but just in case I do I have decanted about 7 ml to keep for myself. If anyone wants the rest they can have it for free.

Maybe use what you nee and pass it on to another Focer.

hi guys just a quickie I have a fazer 1000 2005 it has the ex up valve taken of . now is this a good thing or bad thanks

Hi all u experts...just got new WEMOTO throttle cables for Fazer 600 5DMC (2001)... there is no free play.. even with all adjustment at max...am I missing summat...??!!