ZX14R CT Single Fitting Problems Clearance

Thanks for posting. I'm our Development Manager here at Brock's Performance.  I reviewed your situation on my end and we'd love to help. 

Based on where we're at in the process, the most efficient way of handling is to get the exhaust back in house for our engineering team to inspect. This will allow us to cut out the any guess work and address your problem directly. This will also allow us to replace the exhaust if we determine you've been dealing with a manufacturing issue. 

Are you open to sending the exhaust? 

Thank you, 

Brody 

I'll let you know if additional images are necessary, but I'm thinking the video will do the trick. Thanks for that reference, very helpful.

The purpose of the slotted muffler mounting tab is to allow adjustment. Sometimes it's necessary nudge the system forward before torqueing the mounting bolt [after ensuring the head pipes, collector, elbow, and muffler are seated properly - installing the springs to assist proper seating is often necessary as well]

We may have covered this during the initial troubleshooting process, so let me know if I'm missing something. 

thank you, 

Brody 

Brody

Sorry for the delay in responding, work commitments unfortunately. Thanks for your continued help.

I hope I've described everything clearly.

1: The Oil Cooler has no clearance issues at all . 1 inch at the closest.

2: One Header has approximately 0.080 Thou clearance to the back of the Radiator.

3: Two Sump Bolt Heads have approximately 0.020 Thou clearance to the top of the System where the Headers join the Collector.

4: The 0.020 and 0.080 Thou clearances are approximately the "happy medium"

5: When mounting the Muffler forward , it hits the Radiator before it gets to the forward most positions.

6: I have been told that the Gen2 Engine is taller than the Gen1 Engine.  Could I have been sent the incorrect system for my Gen2 by mistake ?  This may explain the clearance issue.

7: Was the System originally designed to fit the Gen1 ?  I do know that Original Gen1 and Gen2 Headers are NOT all the same.

Please follow the link to google to see some photos. https://photos.app.goo.gl/tLsLSkSoUFFHSFpC9

I couldn't up load photos to the Forum directly.

Regards

Andy

As I watch his vid:

 

Please note – this is a different exhaust (stainless) but the techniques are the same. I would suggest watching it from this point on: https://youtu.be/40oTkAb2zCE?t=674

 

Special note: NO final tightening should be completed until the entire exhaust has been mounted – ALL nuts/bolts hand tight, rotated/adjusted as required and clearance at bodywork confirmed…once done, final torque as required.

 

No signs of wd-40 anywhere – without it, twisting and small adjustments can’t be easily made.

 

6:07 – if the  headpipes are installed first (flange nuts hand tight, one spring on each), the collector can  then be installed and “twisted/rotated” to adjust clearance at the engine.

17:40 – the above will help in this area. While the spring tabs should be aligned, they do not need to be perfectly straight. Additionally, the slot in the muffler bracket allows the system to be pushed forward to create additional space in this area. That said, since the rad is rubber mounted, it may need to either be forced away from the engine, or have a spacer (washer etc…) installed between the bracket and engine to force the rad forward to create clearance between the rad and head pipes.

 

21:00 – Slight rotation of the elbow pipe can also create more clearance at the engine.

 

These systems fit VERY closely, so some bikes require a bit of adjustment to create space. Typically, 1mm between metal parts (min) and 6-8mm between the pipe and plastic (min) is needed.

 

Hope this helps!

You're concern definitely makes sense. I'm glad to say, we have thousands on the road and track and we've done extensive testing ourselves - I'm confident you won't have any issues down the road. 

Thanks again, Andy! I'm glad we could help out. let me know if I can help with anything else.