Install problems - Event Date: January/01/1900 - January/01/1900

Well I have to say that this system wasn't all it was cut up to be as far as the install. The instructions stink and could be more complete showing more of the things that will be in the way when trying to remove the old system and install the new one.  

Then I didn't get any spring tool and any floppy discs w/maps. So now I have to take more of my time to request any maps that I may need.

If any of your installs went super smooth I must be doing something wrong. First of all I did the pre-assemble as told on Step 1 of the instructions. No problem there. I started on Step 1 but after fighting to get the primaries all the way onto the spigots and not all of them would go completely on. I still had about a 1/16" to 1/8" of a gap where it should nearly meet the spigot plate on pipe #1 & 2. Now I got that as close as I could and went onto the next part. The collector was a real pain. I had to use a rubber mallet to get both sides to completely slide on. The left side bottom of the primaries are touching some oil pan bolts. I tried everything to get that away but then it would pull the primaries out again. So I left that and moved on to the midpipe and that went on ok. The muffler went on ok as well but it sure appears the swing arm may hit the inside of it once the bike is off of the stand. Hmmmm....

I trial fitted the under wing and there is no clearance problems there. I guess I could move the mid pipe a little more away so the muffler won't hit.

Now the part I'm really pissed about. I can't get the oil cooler line away from the #4 pipe. It competely rubs and needs to be bent or straightned by at least a 1/4" to clear comfortably. Damned if I can't bend that crap. I tried spacing the cooler with some washers to gain but because it hits right where it turns towards the pipe that won't ever help. So I took the line off and tried to bend it right where is comes out of the cooler. Nope!! Now I need to have a friend straighten it or modify it with a torch. I've been working on this system for over 4 hours. What gives? I took a break and had a fellow biker take a look. He can't seem to see where we could adust anything easily. So I'm pretty sure I 've done what I could do. I'm very dissapointed!!!!!! Once I get this oil line situated and fine tune the fit some more, it better perform or I'm sending this piece of crap back!!!!

TheBird,

Sorry to hear you had trouble with your install. My Brock Hindle couldn't have went on any smoother. The only force I had to use was the slight force necessary to bend the oil cooler line away from the #1 head pipe. This is a known tight area though and was excepted. A slow, methodical fitting and adjustment of all the parts was all that was required to get everything lined up correctly. My kit was missing the spring tool mentioned in the instructions as well but a pair of needle nose pliers worked great.

As for more in depth instructions, I really don't see what they could add. A step by step, bolt by bolt install sheet would be a book. I think a copy of the shop manual would be a good purchase if you plan to do your own wrenching. It has saved me a ton of time and headaches. I don't think it's realistic to expect any parts vendor to provide that level of instruction. I thought the Brock instructions covered all the critical areas concerning the fit and fitting procedures quite well. Just my $.02...

Brock,

My only real issue with the instructions was that they do say that a disk is included with the kit when it is not. I much prefer contacting you and getting the right map for my application but I do think that the instructions should be changed so that they do not say that a disk is included. That would prevent this type of complaint in the future. When the instructions say that something is in the box (disk/map, spring tool) and it's not there, the customer begins to wonder what else might be missing. I know I wondered.

Since I had my system polished by my dealer I just figured that the disk and spring tool might have gotten lost when he unpacked the system for polishing. A quick e-mail to the dealer let me know that his personal system came without the spring tool and that I should contact you for the correct map. Not a problem for me at all, but as you see here, it can put a damper on the buying experience of some people.

Don't stress the small stuff, after you install the whole kit, it will be worth the hassle.  Once you learn how to ride that horse, you'll be a believer.  I don't think there's a busa pkg, that can match BDE products, without cracking the motor open.  One thing it will take is seat time, I'm finding that out, but your numbers will fall weekly, if your a track junkie like me.

Steve, a quick reminder of my pledge to you:

We will send out any replacement part that you may need at no cost!

We will even ship UPS red at OUR expense if needed... credit you for any return shipping charges AND we usually discount your next purchase just for your trouble.

Steve,

Glad to hear it !!....in all honesty, the initial Pipe installs did cause US some small problems at first. 

One of the things we learned is NOT to completely tighten the spigot clamp bolts in the head before inserting the head pipes over them. There is quite a bit of clearance between the spigot and the machined pocket in the head where the gasket rests (we use the same clearance as stock). If the clamps are tightened without being centered.they must be forced in to place. The first sign of misalignment is when the head pipes won't slip all the way down (1/16 gap is typical) the clamp plate. 

This forcing can cause the entire system to bind...which could lead to the clearance problems you encountered. 

We try not to confuse with our instructions...we have found that too much information does baffle some customers. This is why we have left this potential problem out of the instructions to this point..... 

I am now convinced that we need to convey this message across in our instructions. 

Thank you for your input. 

Brock

Yes we have top end kits in stock! Call for pricing per your requirements!  I.E. cams? Pistons and block only?

Dustin