Muzzy Header Install

[gregorytx]

I am in the process of TRYING to install a Muzzy exhaust system. The fit is horrible. The two middle tubes are about a quarter inch off from making it into the exhaust ports after the two outer tubes are loosely bolted up. I have tried getting the middle tubes started first but it's a no go. Anyone else have issues with Muzzy fit? The middle tubes have a crossover welded to them connecting them, so there is no wiggle to 'em to help get 'em in the ports. Very frustrating.

 

[exskibum]

I am in the process of TRYING to install a Muzzy exhaust system. The fit is horrible. The two middle tubes are about a quarter inch off from making it into the exhaust ports after the two outer tubes are loosely bolted up. I have tried getting the middle tubes started first but it's a no go. Anyone else have issues with Muzzy fit? The middle tubes have a crossover welded to them connecting them, so there is no wiggle to 'em to help get 'em in the ports. Very frustrating.

Don't know what to tell you. I had no such issues mounting mine on my '05. I had to rassle with it a bit while on my back, but each of the pipes mated up with the ports just fine. Now, ground clearance on the right side before peg contact when leaned over is another story.

 

[Geezer]

I also had no problem bolting up my Muzzy header once it was wiggled into place. You sure you have the gaskets in all four exhaust ports?

 

[gregorytx]

Called the folks at Muzzy today. Nice people. They told me to ship the header back and they are going to re-jig it and get it in alignment. No charge. In reference to Geezer's question, all four gaskets are in place, that wasn't the issue. The tubes are about a quarter of an inch off from going into the exhaust port. The tubes hit the head and never make it into the exhaust port. If I could have ever gotten them to slip into the port i could have tightened them up no problem. It appears that the center tubes warped somehow during manufacture, possibly removed from the jig before they cooled sufficiently. That's my guess, but then again, I'm told daily how big of a ******* I am, so who knows.........

 

[exskibum]

but then again, I'm told daily how big of a ******* I am, so who knows.........

Let me guess: you're married?

 

[Geezer]

Glad to hear that Muzzy is taking care of you. If it happened to me I would have been tempted to try to form them myself and probably made things worse. Let us know how they fit when you get 'em back.

 

[gregorytx]

but then again, I'm told daily how big of a ******* I am, so who knows.........

Let me guess: you're married?

I WAS married, but she still lets me hear it,,,voicemails, texts messages, e-mail, yada, yada, yada........

 

[I'mAllIn]

Mine fit like a charm. While others have reported rubbing issues during deep lean angle on the right side, I've had no such issues with my fat a$$, although my bike has GP Suspension forks and a Penske shock.

I'll assume you have a PCIII (if not, get one NOW). I have the combination Wally Smoothness (below 3500 rpms) & Muzzy (over 3500 rpms) map and it works like a charm.

Good luck.