Problem 2:
Melted Alternator Cover. Why they made it plastic I don't know, but I can tell you the stock exhaust is way below it, the Muzzy #2 Head Pipe goes right beside it and includes the heat shield you can see attached to head pipe #2, but the plastic still melted. I also since I had wrapped my head pipes, had to open up the air gap on the Muzzy shield a little to allow better air flow. (You can see in the pics.
How to route the head pipe 2 farther away from the plastic is something that I am having a very hard time figuring out. I worked on it for a LONG time and got it as far away as I could. Obviously not far enough. Also, if even with wrap and the shield, it still melts the alternator cover, what about all the factory wiring also in very close proximity to the front head pipe #2? Is this a long term viable system for the Teryx? No so sure myself.
I really like this system, but I am not sure at all how to solve these problems. I am probably taking my headpipe #2 and rear headpipe #2 collector to have bungs welded on, would it hurt to have them cut about 1/2 to 3/4 inch out of Headpipe #1 so it will not contact the front heat shield? If it would hurt, I think I will be taking the stock exhaust and having the bungs welded on it and shelf the Muzzy's a while so I can just ride instead of dealing with self induced upgrade issues. DOH!!
Also, I emailed Muzzy's about the front heat shield contact and melting alternator cover on Tuesday and have not heard back. I will try to call them and point them to these photos today so they can see and hopefully have some ideas to make this work out. I like the exhaust, but it so far has been way to much maintenance.