Removing Cats from Stock Headers = Full Exhaust - Page 2 - ZX6R Forum
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post #16 of 30 Old 09-20-2014, 03:19 AM
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It is hard work.
If I were to do another one, I'd use a plasma cutter.

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post #17 of 30 Old 09-21-2014, 06:39 PM Thread Starter
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Took me about 2 hours with a chisel and hammer
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post #18 of 30 Old 09-25-2014, 01:30 PM
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I ended up getting MJS headers for my 2014, because I needed an O2 sensor bung. I couldn't seem to find anyone who would weld the bung up for me without it costing me $80. I decided to say F that, I will find someone eventually..

So if anyone wants a set of 2013-2015 headers with the catalytic convertor removed, I have a set. It's the exact same thing as the MJS Headers, except it's not painted black, which smelled for a week by the way.

I now see that Arrow makes a set of headers you can buy separately for the 2013+ bikes.

Nice revival on an old thread

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post #19 of 30 Old 09-25-2014, 04:22 PM
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Well see what you need to do to get the cat out of the header is you get another cat and tie a rope to it and throw that cat into the header. The cat with the rope will lure the other cat stuck and then you can yank em both out at once.
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post #20 of 30 Old 09-25-2014, 05:45 PM Thread Starter
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Well see what you need to do to get the cat out of the header is you get another cat and tie a rope to it and throw that cat into the header. The cat with the rope will lure the other cat stuck and then you can yank em both out at once.
you are very succinct
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post #21 of 30 Old 09-26-2014, 06:35 AM
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I don't see how anyone could remove the cat out of the header without removing the header off the bike. I guess it would be possible but would be so much more difficult than removing the header.

You can remove the header without removing the radiator it just takes some patience and multiple wrench options. Once the header is off it's pretty easy to get the CAT out by drilling around the perimeter of the honey comb and chiseling it out.
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post #22 of 30 Old 09-26-2014, 07:18 AM
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post #23 of 30 Old 12-18-2015, 11:43 PM
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friends , is there same procedure on zx6rr 06 want to cut out cat from my headers too . and also removed servo butterfly from muffler . what you think about it , and maybe someone done it before ?
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post #24 of 30 Old 12-19-2015, 06:15 AM
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I just leave my cat in there.

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OMFG.... I can't stop laughing!

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friends , is there same procedure on zx6rr 06 want to cut out cat from my headers too . and also removed servo butterfly from muffler . what you think about it , and maybe someone done it before ?
Take a drill... put a large bit in it. Press trigger on drill... apply pressure to honeycomb lookin' thingy in your pipe. Keep going. Drill baby drill. Then pound the rest out with a screwdriver. Clean up inside with dremel if available.

That's pretty much how I did mine.

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post #25 of 30 Old 12-15-2016, 12:44 PM
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I did this and it took me hours. It sucked and I still left maybe 10% of the material in there calling it quits. Made a nice change though.

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post #26 of 30 Old 12-15-2016, 12:52 PM
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I did this and it took me hours. It sucked and I still left maybe 10% of the material in there calling it quits. Made a nice change though.
Took me about 20 minute with all material removed... Proper tools make a world of a difference.
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post #27 of 30 Old 12-15-2016, 12:59 PM
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Took me about 20 minute with all material removed... Proper tools make a world of a difference.
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Yeah. If I had a really strong drill I bet it would have been fast. I used a holesaw and a chisel.

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post #28 of 30 Old 12-15-2016, 02:22 PM
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A few tips:

-Remove the header from the bike
-Drill holes on the outside of the material to disconnect it from the wall of the collector
-You can use a bigger drill bit if you need to make the hole bigger to allow the cat material to fall out in one piece

It literally took me 15-20 mins to get everything done.
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post #29 of 30 Old 03-06-2017, 04:50 AM
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Sorry to drag up an old thread guys, but I am thinking of doing this.
My question is this.

Is it a good or bad idea to remove the o2 sensor when removing the cat? Will the bike run ok with it removed with a PCv fitted and dynoed?
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post #30 of 30 Old 03-06-2017, 07:40 AM
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Quote:
Originally Posted by Schooley View Post
A few tips:

-Remove the header from the bike
-Drill holes on the outside of the material to disconnect it from the wall of the collector
-You can use a bigger drill bit if you need to make the hole bigger to allow the cat material to fall out in one piece

It literally took me 15-20 mins to get everything done.
15 - 20 I'm jealous, I did this and even with opening up the exhaust and knocking the cat out it took about an hour. All put back together and Bazzaz installed so I'm happy
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