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fmf powerbomb header issue?

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ok. i bought a new fmf powerbomb header for my sons crf250r.

Came in sealed fmf package. went to install today and the studs in the head are to short or the fmf header sleeve and the bolt flange are to thick?

i cannot see enough stud to get the head pipe bolt started?

check box and header model no on fmf web site and it is correct?

any one else with fmf header have this issue?

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ok. i bought a new fmf powerbomb header for my sons crf250r.

Came in sealed fmf package. went to install today and the studs in the head are to short or the fmf header sleeve and the bolt flange are to thick?

i cannot see enough stud to get the head pipe bolt started?

check box and header model no on fmf web site and it is correct?

any one else with fmf header have this issue?

Mine went on ok but it was close. I just about go tth enuts on so I Loc-Tighted them to make sure they wouldn't come off. Is there a copper shim in the head? Maybe it's too thick?

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I checked for the copper shim but I didnt see one.

May go to muffler shop tomorrow and see if they can fab me a sleeve about 1/2 the width of the one that came with it.

I measured the stock distance between the header flange and the header bolt sleeve. It was 5/8 inches. The FMF was almost 7/8 inches.

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Not meant as a jab, but that's a bad deal from FMF. You should make a call to them too and give them a shot a correcting the problem.

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Yeah.....that is my plan to give FMF a call.

Offices only opened M-F.

But I was trying to determine if this was a common occurrence with FMF and to try and find out what other peoples solution was if it was common.

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LOL

Finally figured out issue with FMF header fit.

Was trying to put on 2nd hand 08 crf250r bike.

Took stock header off my 06 crf250r and tried and fit like a champ?

Noticed the header exhaust manifold looked different between the bikes.

I took my sharpest flat head screw driver and bent at 45 degrees. Wasnt my favorite screw driver so no loss.

Was able to finally loosen what looks like a 3/8 inch aluminum exhaust washer out. What the &@#&$?

I will take pics and post. Never seen anything like it?

On my 06 that is stock I saw the stock cooper washer but not sure what this thing is or what its intent was?

Probably some racer secret that gives you 20+ extra HP......hahahahahha!!

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Here is foreign object that was causing FMF header fitting issue. The object on left is foreign object. Object on right is stock exhaust header copper washer.

Anyone know what the foreign object is for or why it would be in the header?

IMG-20111220-00041.jpg

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My 08 has a graphite kind of gasket, not a copper gasket. Its stock exhaust so i know it was never changed. The one you show its weird, i'd just throw a OEM gasket on it and call it good! :bonk:

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That looks like an exhaust gasket from a Cometic gasket set

Hmmm. I will check there website.

Thing that fooled me was in the header being silver it looked like part of the header. At least the stock brass washer is identifiable. It was not crushed or deformed at all like the stock.

Even after I was sure it wasn't part of the header by comparing to my stock 06 I had to take a few whacks at it with a hammer and altered screw driver to remove.

All good now....live and learn:bonk:

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Hmmm. I will check there website.

Thing that fooled me was in the header being silver it looked like part of the header. At least the stock brass washer is identifiable. It was not crushed or deformed at all like the stock.

Even after I was sure it wasn't part of the header by comparing to my stock 06 I had to take a few whacks at it with a hammer and altered screw driver to remove.

All good now....live and learn:bonk:

If it was a cometic gasket, then it was probably made of stainless steel. That would explain the screw driver giving up. :bonk:

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That looks like a TUSK exhaust gasket

They are stainless or aluminum and do not really compress

much. I had same problem with a OEM header and TUSK kit.

I re used OEM gasket and talked with ROCKY MOUNTAIN

about it but did not get any "real" answer

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You may be correct.

I havent found the gasket anywhere yet. But it is a weird one.

I purchased 3 honda stock brass gaskets. Work and fit perfect plus that is what FMF instructions recommend.

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