WTF: Kerker 2-in-1 exhaust, bolts from engine too short?

[iplante]

Hey guys

So today, I finally got around to installing my Kerker 2-in-1 exhaust system.

I took the old system off, and put the new gaskets in and then tried to install the new header. And then I noticed it doesn't quite work. The bolts from the engine are too short and I can't bolt the new header on.

The OG system has these collars that come off in two pieces each, right? The new system's collars seem to be soldered on, they are part of the header pipe. I may be able to grind the new collar but that'd be a pain in the butt and I'd rather not.

I know a few people here have a Kerker system, and a lot more have the Muzzy system. Have any of you encountered this problem?

Thanks!

[iplante]

Paging @CZroe, since I know you have a Kerker!

[choneofakind]

Can you take a picture for us? I'm not sure what method exactly the Kerker uses to attach, but I know my Muzzy didn't need new gaskets or anything; just the headers, which bolted right up.

I don't think they'd manufacture an aftermarket system that required you to change out the bolts coming out of the head.

[k-os]

Did you check that the old exhaust gaskets were out of the head, before putting the new ones in? They may be hard to see if they're blackened from the exhaust.

[iplante]

Yep the gaskets are off and there's no grime buildup in there either.

Attaching pictures.

[iplante]

Another

[crimsondragon]

Bolts or studs? If someone removed the studs and used bolts, just get longer bolts.

[iplante]

Sorry, studs.

I can't even get a nut started to tighten it

[crimsondragon]

Can you verify with a stock exhaust that the Kerker is longer? If it is then we'll work on solutions.

[iplante]

Yes the collar is longer on the Kerker. I can take comparison pics if you want tonight or in the morning.

[crimsondragon]

That's ok, I believe you. It's unfortunate and weird it's longer. You'll just have to remove the old studs and either go with longer studs or bolts. Jam two of those exhaust nuts together on a stud with the flanges facing each other. Then with a wrench on the nut towards the engine, turn the stud out. You will most likely have to use a support wrench on the outer nut to keep it tight against the other nut. You could snap the studs, so use some PB blaster and a torch on the engine, not the stud. They should come right out. Once you get out all 4, you can use them to determine the proper length you'll need. They're 6mm x 1.00 thread pitch.

*edit*
Actually instead of removing the studs, see if you can use the unused holes that are opposite the studs. I just went outside and saw them on my bike.

[CZroe]

I'll take a look and get pics when things dry up and I have some daylight. I'm working 12 hours a day ("open to close") 7 days a week now so I dunno when that might be.

[iplante]

Originally Posted by crimsondragon

That's ok, I believe you. It's unfortunate and weird it's longer. You'll just have to remove the old studs and either go with longer studs or bolts. Jam two of those exhaust nuts together on a stud with the flanges facing each other. Then with a wrench on the nut towards the engine, turn the stud out. You will most likely have to use a support wrench on the outer nut to keep it tight against the other nut. You could snap the studs, so use some PB blaster and a torch on the engine, not the stud. They should come right out. Once you get out all 4, you can use them to determine the proper length you'll need. They're 6mm x 1.00 thread pitch.

*edit*
Actually instead of removing the studs, see if you can use the unused holes that are opposite the studs. I just went outside and saw them on my bike.

Thanks for the reply! The unused holes are only on one side of the headers, not the other. I'll see about taking the studs out, thanks! I've never used a torch or PB blaster.. I'll see if I have a friend that has.. lol

@CZroe, thanks for your reply. That's quite a schedule! I was just wondering if you remembered having a hard time installing yours or if it bolted right in without any mods. No need for pics

[iplante]

OK, tonight I'm going to reinstall my stock exhaust.

Tomorrow night, I'm gonna ride it the 2 mins to my friend's shop and he's gonna help me take the studs out.

[alex.s]

the studs aren't that hard to remove, just take them out and replace them with longer bolts. large vice grips should be enough. if not you could weld (or epoxy) a nut on the end then use a normal closed wrench to remove it. remember to tighten the new bolts evenly to avoid bending the plate or bolts

[iplante]

Thanks, Alex I'm going to my friend's shop tonight to work on this.

I reinstalled my OG exhaust last night for the ride down to his shop... it was a ****ing pain in the ass let me tell you. Stupid radiator in the way...

He has lifts at the shop that will make my life so much easier. Having the parts at eye level will definitely help while I work on it.

[CZroe]

Originally Posted by iplante

@CZroe, thanks for your reply. That's quite a schedule!

Yeah, which is why I haven't been on here all Summer. They keep firing the other guys because they aren't clones of me. Even when they hire someone else it's always part-time (28 hours) and they still work me 50+ hours a week.

Originally Posted by iplante

@CZroe, thanks for your reply. That's quite a schedule! I was just wondering if you remembered having a hard time installing yours or if it bolted right in without any mods. No need for pics

It was installed by the previous owner and was really loose so I'm not even sure it was installed right but I will take a look when I get some time off with daylight!

[iplante]

OK, so turns out I'm just retarded.

Having the bike eye-level on the lift really helped. One of the collars was a bit bent so that's why I couldn't get it all the way in. So the headers really did fit after that was taken care of.

We were able to install it properly and man does it sound sexy compared to the OEM setup. Thanks for your suggestions and your help guys

[Dragone]

right on, congrats on the fix.