Exhaust pipe removal

[ram04]

That sucks, sometime I think not all of the pipes that are made are exact, I bought a HMF system and the head pipe would'nt fit in the silencer, I had to use a brake wheel cylinder hone to open it up, went thru two sets of stones before I got it to fit. At the price of the Muzzy pipe it should just about install itself, LOL! Good luck on it I'm sure you will figure it out.

[Magellan]

OK here are some photos.

First: How to make front headpipe #1 not hit front Teryx Heat Shield? No matter how it is rotated, there is no way other than modding the heat shield with my particular head pipe to make it not hit the shield. Even if I rotate the pipe to where it would never work with Headpipe #2 and it is the most out of the way as I can get it, it still touches the heat shield.






There is no way for me to make the head pipe #1 not hit the factory heat shield. In the below photo, the heat shield needs to be pushed back at least another 1/2 to 3/4 of an inch to attach it with the factory strap and it is already touching the head pipe.


5 pic limit, so continued... Sorry

[Magellan]

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.

[Jaybo700R]

Its odd that you have clearance issues up front though, that surprises me as I have no clearance issues anywhere. I'm waiting for exhaust gaskets to come in so no miles yet. You could try doubling up the wrap? Also, I wrapped the pipes all the way including where the springs were, just left enough loop showing to reattach the spring. I then went over the whole pipe again over the top of the first layer with a 2nd layer.

[TERROR-X]

Magellan, sorry to hear about all the pain your having with the system. I also had issues at first with my plastic cover, but never had any issues with the front clearance. I believe that the gasket problem has been a pain for everyone that has the system, it really does,for lack of better words, SUCK. But the sound and performance of the muzzy is EXCELLENT!

My best advice in fixing your clearance problem of the plastic cover is as follows:
Once the system has been fully installed make sure the muffler brackets are fairly loose, and go in through the cockpit (driver side) and loosen the header bolts just enough to have some play without the gaskets coming out of place. Then grab hold of the header just down stream of the plastic cover heat shield and and work the system upward. It will take some force, but I assure you from my experience there will be no damage done. The correct position of the head pipe should be out and above the plastic cover.

I have about 2" space between the shield and plastic cover and have rode as hard and as long as possible in the Arizona heat, and have had no melting problems. I dont even have any heat wrap on. I have removed the stock shield that you were having problems with and have not even used the muzzy mtr mount shield yet. Absolutely no heat problems in the cockpit at all. However I did have some factory wires beginning to melt, but that problem was easily eliminated by rerouting them.

Now your excessive heat problems sound like they might be caused by too lean of jetting. What jets are you running? I'm running the biggest jets from Todds kit and she's still kinda lean. Now the only problem that I face, but not really worried about, is my right muffler sticks out about 3/4" longer than my left one. I wont fix until I see that it's a performance issue. I have about 20hrs on the muzzys.

I hope some of this helps you out buddy....................

[Magellan]

Originally Posted by TERROR-X

Magellan, sorry to hear about all the pain your having with the system. I also had issues at first with my plastic cover, but never had any issues with the front clearance. I believe that the gasket problem has been a pain for everyone that has the system, it really does,for lack of better words, SUCK. But the sound and performance of the muzzy is EXCELLENT!

My best advice in fixing your clearance problem of the plastic cover is as follows:
Once the system has been fully installed make sure the muffler brackets are fairly loose, and go in through the cockpit (driver side) and loosen the header bolts just enough to have some play without the gaskets coming out of place. Then grab hold of the header just down stream of the plastic cover heat shield and and work the system upward. It will take some force, but I assure you from my experience there will be no damage done. The correct position of the head pipe should be out and above the plastic cover.

I have about 2" space between the shield and plastic cover and have rode as hard and as long as possible in the Arizona heat, and have had no melting problems. I dont even have any heat wrap on. I have removed the stock shield that you were having problems with and have not even used the muzzy mtr mount shield yet. Absolutely no heat problems in the cockpit at all. However I did have some factory wires beginning to melt, but that problem was easily eliminated by rerouting them.

Now your excessive heat problems sound like they might be caused by too lean of jetting. What jets are you running? I'm running the biggest jets from Todds kit and she's still kinda lean. Now the only problem that I face, but not really worried about, is my right muffler sticks out about 3/4" longer than my left one. I wont fix until I see that it's a performance issue. I have about 20hrs on the muzzys.

I hope some of this helps you out buddy....................

Thank you for the advice on the plastic cover Terror-X. I think my main problem stems from the to long front head pipe, it makes it so the farther I push the Header Pipe #2 upward to clear the plastic the worse front head pipe #1 hits the front heat shield. I took the pipes to have the bungs welded on today and I was very tempted to get the guy to cut out about 3/4" from the front head pipe #1 so it would not contact the heat shield. Hopefully I will hear back from Muzzy's at some point about what to do, it is not acceptable that on a 1K exhaust system there is no way to make it not contact factory heat shields. Once that problem is solved, I will do as you say and forcibly push upward on the headpipe #2 to get it high enough to clear the plastic alternator cover. Hopefully I can do that. The welder who is doing my bungs in the #2 head pipes said if I space the Muzzy front head pipe #2 heat shield out from the pipe a little more it would probably help as well.

I do not think I am lean, I am running about 12 sizes larger than what Muzzy recommends, although it is down 2 jet sizes from what I originally installed when I got the HW kit. As soon as I get the #2 head pipes back, I will have the A/F Meter to see if I am lean or rich. I think I am still rich with both TPI's closed, but I will find out for sure next week even if I have to leave the front heat shield and plastic off for testing.


Jabo, I thought about extra layers of wrap, but on the directions for the wrap it says not to do any more than a 1/2" overlap or you can cause damage to the pipes. I have no idea if you can or cannot, but I followed the directions. I love the wrap my heat has been reduced in the cockpit by at least 50 to 70% I would estimate, even the wife noticed. Is it OK to wrap more than one layer, if it is I'll be doing the whole thing as well.

Anyway, will probably send another email to Muzzy in my spare time tonight with the photos I took this morning. Thank you for the help and advice guys!!

If you are an expert and you know if it is OK or NOT OK for me to get the welder to cut 1/2 to 3/4" out of the #1 head pipe then reattach, PLEASE let me know. I could have it done and back installed and RIDING by Tuesday.

[Jaybo700R]

Magellan, I would call the Muzzy guys, They are going to be a lot more responsive to phone calls than Email. I asked the same thing of the local speed shop where I got my header wrap, as when I ordered the first stuff online the instructions said to do as you mentioned, 1/2" overlap. That's what you want to do on the first layer, yes, but according to the guy at the local speed shop where I got the last roll, he said it makes no difference if you want to add another layer. He's been around automotive speed shop applications for decades, but he has never heard any problems with double wrapping pipes.

Again though, I would be calling Muzzy directly point them to the email, or the thread, and let them check it out. From talking in person to the R&D and the marketing guy I think they will stand behind their product 100%, even if it means sending you another pipe. Your clearance issues don't make sense to me, I have plenty of clearance on my pipes...

Terror-x's cooments about working hte pipes upwards is exactly what the R&D guy told me about installing mine, Sorry I did not make that clearer.

[Magellan]

Originally Posted by Jaybo700R

Magellan, I would call the Muzzy guys, They are going to be a lot more responsive to phone calls than Email. I asked the same thing of the local speed shop where I got my header wrap, as when I ordered the first stuff online the instructions said to do as you mentioned, 1/2" overlap. That's what you want to do on the first layer, yes, but according to the guy at the local speed shop where I got the last roll, he said it makes no difference if you want to add another layer. He's been around automotive speed shop applications for decades, but he has never heard any problems with double wrapping pipes.

Again though, I would be calling Muzzy directly point them to the email, or the thread, and let them check it out. From talking in person to the R&D and the marketing guy I think they will stand behind their product 100%, even if it means sending you another pipe. Your clearance issues don't make sense to me, I have plenty of clearance on my pipes...

Terror-x's cooments about working hte pipes upwards is exactly what the R&D guy told me about installing mine, Sorry I did not make that clearer.

I will try to call today. My problem is I live in EST Zone and I work from about now every day to about 2 EST then sleep, so I have a very small window of time to work and also deal with this on the phone as they are 3 hours behind me in PST Zone.

I really think that my front #1 head pipe is to long and if it was shortened, I could get the front #2 head pipe higher up and clear of my plastic cover.... although will it not then hit the rear frame cross member if it is that high. Something is definitely not right with my setup and I am not the only one with this exact problem. I have heard from people with my problem and also people with hitting the rear cross member problem as well.

Thanks for the info on the wrap. I will double wrap mine as well then. It makes a HUGE difference in heat in the cockpit. Definitely worth the effort, I bet it would cool down the cockpit a huge amount to wrap the factory pipes as well for you guys not liking the heat.

[Jaybo700R]

Mine does not hit any of the cross members, it's closer up by the seat but not that close. The R&D guy (who I can't for the life of me remember his name) showed me the placement on their Teryx. Mine went in fairly easily, but with all the pipes and getting them lined up properly so everything is square to the engine head seems to be the battle (not to mention the gaskets) to be won.

Perhaps they should put marks on the end of each piece to easily line everything up properly?

Hopefully you can find the time to connect with them and get this figured out. I'll try calling today and see if I can get them to come in here and take a look at this thread..

[Jaybo700R]

I called and spoke with Curt at Muzzy's just now and let him know about this thread and he assured me that he will forward this to the appropriate people and get this addressed ASAP. Holiday weekend though, but we might even get it addressed or answered today. Hope this helps!