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Thanks for the solid input everyone. Between the solid recommendations here, the guys at Attack, and Wade, we’ll get an accurate result. Separate note: it’s a good thing we had the injectors serviced - see printout below. Valve adjustment is taking place now. I’ve got a tech support ticket opened up w K&N to engage them in the search for the big mouth HA-8098. Even after putting photos of the two animals that both have K&N part number HA-8098 stamped into them, K&N is having a hard time getting their arms around the concept.

PS on the O2 sensor per header, I think you will find that your guys are living in the old world ! All modern O2 sensors are electronically heated so can operate anywhere in the exhaust system. The old ones were heated by the exhaust flow, so were best placed in the first 10"' of the header to ensure they heated up quickly & maintained an operational temperature. The new ones, can be anywhere in the header & get the same result. Resessing them from the header, so that the sensor tip is flush with the ID of the pipe, actually creates an eddy zone that should in theory make their reading more average, but they are best placed with just the triangular tip section protruding inside the ID of the pipe, being offset to one side they will not cause a full reflective pulse & should not hinder gas flow. But if mounted on a standard bung, they can protrude quite a ways into a primary header, much less so in a secondary or later collector, thus one sensor where mine is has a very minor impact on flow, as the pipe cross section is much larger.

Again, as to the air filter. As long as ALL dyno runs are done with the same filter in generally the same clean condition that is all we can hope for. We are building an exhaust system and not the total bike, so: 1. Keep ALL other parameters static apart from fueling changes. 2. If it is an oiled filter, clean and oil it and run the bike with it for say 50/80 km BEFORE the first dyno run. 3. DO NOT alter the air filter between runs unless it has become contaminated in some way. Honestly, to get the most consistent readings, a new standard paper filter would probably be the best way to go. Remember, we are testing exhausts and nothing else. So, get the fueling right with the standard pipes, read the power curve, then rinse and repeat with the new pipes.

Here it is...a real header made of real molecules. There are a number of extra welds - especially in the primaries - because this is a built-from-scratch prototype. The welds along the primaries, secondaries, and collector will not be present in the production headers because the bender vendor will be setting up a mandrel to bend all the tubing to Wade's specifications, so he won't have to weld shorter sections together as he did on the prototype. We'll be heading over to pick up the prototype tomorrow afternoon or next Wednesday. We've got the exhaust off of an innocent donor 5th gen and will take the bike to Wade's shop to confirm fitment or make adjustments on site. It was a little nerve wracking that he built straight from the TBR without confirming fitment, but if he's not worried about it, we're not worried about it!

As said, it seems that every '98 owner in Italy gets bad mileage, regardless of the injectors conditions or the speed. Y2K catalyzed models are known for having a MUCH lower fuel consumption. The bike runs great anyway.

185?!? Holy smokes!!!!! I’d say she and the rider are doing just fine... C Sent from my iPhone using Tapatalk

Updated version with everything in place 🙂

Gotcha on that, thanks Terry. I spent 12hrs cleaning the carb rack just to make it run and I still have some issues with it. Damn bike has standed me twice, flooding on deceleration. I have dropped the needles one stop and it got better. I now have an optimised needle and jet kit on order hopefully this will set things right along with a heap more time in the ultrasonic bath and some new carb seals. I will check those tubes again when I get back into the carbs. The bike is for my girl, its got a low seat for its size, good for her... I like making old things new again, so its good for me too! Needless to say her mum hates it? You can't please all the people all the time. (A Blue Gen5 VFR pleases me!)