Gen 1: Headers, what will fit?

[jwebsta32]

Will any aftermarket header from a Gen 2 or Gen 3 fit a Gen 1?

[bluedevil]

Before anyone asks do a search I told this member in a PM to start a thread after a search so thanks in advance for the help to this member.

bloo

[-Op-]

Personal experience I cannot comment. However, Gen 2 and 3 stock headers are supposed to be a direct bolt-on affair to a Gen 1

[filthy phil]

someone lmk if there is any errors

Swing Arms

04-09 swing arms are interchangeable with no modifications. Of course exhaust will have to be changed or modified to match. The 08-09 is more ridged, and a 1/2" longer than 04-07. They also set rear ride height up 1/2" from stock setting. They are 1 lb lighter.

Front Forks

04-09 front forks are all interchangeable along with triple clamps. The internals where progressively modified, the best being the later years. But all internals are interchangeable. Note: while the front forks are interchangeable the 04-05 front wheel will need spacers made to be accepted for the front axle.

Calipers

04-09 Front & rear calipers are all interchangeable along with master cylinders and brake lines. 04-07 are virtually the same in operation and are very poor. 08-09 are an upgrade and much better. Changing lines and pads do little to improve them.

Rear Shocks

04-09 Shocks and linkages are all interchangeable. Like the forks they where progressively changed the later years being better. But note: 06-07 have reservoir facing opposite side for exhaust reasons. Makes no difference other than ease of mantinence.

Engine and Transmission

04-05 has a lighter crankshaft and different alternator arrangement. It is not interchangeable with 06-09. Unfortunately I can not comment on the transmission though I suspect it is the same. 06-09 transmissions are completely interchangeable along with the clutch, oil pump and water pump. The inner shift linkages are different and require some modifications to switch to later model. The 08-09 clutch has a slower drive gear built into the basket to slow down the water pump, you will also need the oil pump drive gear to go with it, they all fit right in. 08-09 has a different 1, 4 and 5 th gear to fix the weird ratios in the 06-07 transmission. They altered just the drive gears and are the same diameter but have one less tooth on each gear. Shift drums are different on top where the shift linkage goes only and so older shift drum can be retained if changing transmissions for ratio advantage.

Outside shift linkages on 04-05 are different ratio although they will bolt right on. They will require more travel to operate.

Exhaust

The header exhaust are interchangeable 04-09, meaning they will fit in the head. But of course all 3 generations have different end pipes. 04-07 are all titanium, and 08-11 are steel and the converter is built into the pipe, unlike the 06-07 has a bolt on converter.

Wiring

None of the wiring from 04-09 is interchangeable, that is not directly. Some plugs will fit but best to stay to your generation. Wire colors are very close but again not the exact same. Computers are not interchangeable.

If you find any of this information not to be correct please let me know so I can change it. This information is for the experimenters use and I have found these facts to be so. But there are exceptions to everything. I tried to be thorough and am sorry for any mistakes.

Skeet Wyman

[jwebsta32]

Thanks for the info

[rafa]

Originally Posted by filthy phil

someone lmk if there is any errors

I see a lot of wrong stuff there.
All the swingarms are interchangeable but the 3rd gen is deff shorter than the 1st gen.

The 3rd gen calipers will bolt but the discs will have to be changed too because they are larger than the 1st and 2nd gen.

[bluedevil]

Originally Posted by rafa

I see a lot of wrong stuff there.
All the swingarms are interchangeable but the 3rd gen is deff shorter than the 1st gen.

The 3rd gen calipers will bolt but the discs will have to be changed too because they are larger than the 1st and 2nd gen.

the OP don't care about errors in the other stuff....can you confirm or at least keep on topic the info. this member is looking for does a 2nd -3rd Gen header fit a 1st Gen? ...would be good to know as well even if they fit are there any fitting issues with link pipes to clear the oil reservoir and add your link pipe for other manufacturers.

bloo

[rafa]

Originally Posted by bluedevil

the OP don't care about errors in the other stuff....can you confirm or at least keep on topic the info. this member is looking for does a 2nd -3rd Gen header fit a 1st Gen? ...would be good to know as well even if they fit are there any fitting issues with link pipes to clear the oil reservoir and add your link pipe for other manufacturers.

bloo

The stock header of a 3rd gen does fit for sure. but it will touch the belly pan in some places, so either you trim the belly or it will melt.
Cant comment on aftermarket ones, but if i had to guess i would say it is even worse since the tubes will be larger.

[bird_dog0347]

Originally Posted by rafa

The stock header of a 3rd gen does fit for sure. but it will touch the belly pan in some places, so either you trim the belly or it will melt.
Cant comment on aftermarket ones, but if i had to guess i would say it is even worse since the tubes will be larger.

Are you sure it wasn't the CAT touching the belly with the 3rd gen header? The stock one has it built in and it is by far the biggest piece, much larger than the tubes.

[rafa]

Originally Posted by bird_dog0347

Are you sure it wasn't the CAT touching the belly with the 3rd gen header? The stock one has it built in and it is by far the biggest piece, much larger than the tubes.

It is both, but since they are connected im counting as one.