Quote:
Originally Posted by Jaybo700R
Sorry for the long delay, Life got busy for a while and I had to neglect the board for a bit. Anyway, I am waiting to try it out, Even with the glue the exhaust gasket slipped and I had an exhaust leak - With all the sound/heat insulation I didn't hear it. Anyway, I am now waiting for the new gasket to come in as I crushed the old one.. Hopefully it will be in next week as promised.
Hopefully Muzzy will improve the gasket situation too, their system seems to be the best out there, but for the price you would think they would have a better flange that makes it simple to be positive the gasket stays in place and seats to the head properly.
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I agree with you on the header gaskets. Believe it or not installing the rear was the hardest and most frustrating thing I have ever done on my Teryx. I have installed HW kit complete with airbox mods, UNI filter, Power Steering, rejetted multiple times and the Muzzy install was by far the hardest. The problem is that grease will not do the trick when you are manipulating the rear header and pipes. You cannot tighten anything until you get it all lined up and by the time you do, the gasket is sitting on the engine case and no longer anywhere near the exhaust opening or flange. I went and bought 4 more new kawa 11009-1894 gaskets today since I had to take the rear header loose to get the system off to get the bung welded on. I am really dreading putting it back on... surely 4 tries I can get one on well enough. Also, my kawa plastic Alternator Cover is melted through I discovered today in spite of the Muzzy's heat shield. Had to order another, I went ahead and got 2 just in case 13.90 each. Gotta now figure out how to keep the next one from melting since the Muzzy heat shield on pipe 2 did not work for me and I paid very careful attention to the clearance between the pipe and plastic cover and routed the pipe as far away as I could get it. Also, the front header pipe hits the metal heat shield up front that is factory Kawasaki. Not sure how to cure that either, I can't see any way to make it not hit it unless I do some bending on the heat shield itself. The Muzzy front cylinder header is fixed length between the flange and the bend. How do I change that to make it not hit the factory heat shield... Impossible, yes, so heat shield has to be modded I guess, I definitely cannot shorten the length between the flange and bend. THe header wrap is eaten through and there is a big burn mark on the insulation on the back of the heat shield from contact. Also the add-on Muzzy's heat shield that attaches to the left rear motor mount with the glued on insulation - the insulation is falling off, the glue did not hold. Photo tomorrow.
Overall, after discovering the fit and finish and melting, etc with the Muzzy's install after the time it took to put it on, I am a good bit frustrated. Way to hard to make the system work IMHO for the price. Fitting a few pipes together should not be rocket science, but I cannot for the life of me figure out how to avoid hitting the front heat shield that is fixed to the frame and also routing the pipes away from my alternator cover enough to keep the plastic from melting. I spent about 6+ hours installing this system and I had the Teryx winched up into a tree so I had very clear access to the bottom and top of the machine and I worked long and carefully on the pipe routing to make it the best I could get it. I will decide over the long weekend if I am going back to the stock or another manufacturer or what.
I know this sounds really negative and I am definitely frustrated and have never had so many issues with a single install. Maybe it is just my lack of exhaust system experience, but I put a Banks system on my last truck and a system on my Vinson.. I think I am going to mix a drink and watch some TV for a while.
I will take photos to document what I am saying, I don't have time tonight, they will be posted tomorrow I promise. I know this is a negative post from me and not the norm but this system is in my humble opinion not ready for prime time . It just does not fit that well and the add-on Muzzy's heat shields do not work in my case, neither one does what it is intended to do it seems.