Hi guys, had a boz exhaust (not best, I know) and finally came around to installing it but ran across some problems. The exhaust is states it is for an 06-07 bike. I remember the PO of the bike telling me he bought the bike with a Two bros exhaust and it was too loud for him so he reverted back to a stock exhaust. I never asked if it was a full system two bros and if he bought a set of stock headers along with the stock mufflers. I have a suspicion that he bought 08+ headers as well. Can you guys confirm it for me?

The issues I am having with fitment is that, the the cans are having issues clearing the passenger pegs, and they seem to angled up, impeding the heal of my boot when on the bike. Am I just doing it wrong? or is it indeed the wrong headers?. Will I need to pick up the right year headers or is there some modification that could be done?

This member has the same exhaust and what it is supposed to look like.
cant find other pictures. https://zx14ninjaforum.com/messages.cfm?threadid=B41D3543-D56B-84E2-15BC1CF382C369AB

here are the headers, cant tell if I have the cats in my header or not, I don't see O2 sensors.
http://i3.photobucket.com/albums/y65/bigjoe87865/20140206_105847_zpsd3dc1b6a.jpg
http://i3.photobucket.com/albums/y65/bigjoe87865/20140206_105900_zps597ff87d.jpg
http://i3.photobucket.com/albums/y65/bigjoe87865/20140206_110523_zps8626d78a.jpg

and the bike with the exhaust test fitted. Not clearing the passanger pegs and they are lopsided
http://i3.photobucket.com/albums/y65/bigjoe87865/20140206_110212_zpsf7af887e.jpg
http://i3.photobucket.com/albums/y65/bigjoe87865/20140206_110226_zps709b6893.jpg

Thanks in advance guys!

* Last updated by: bigjoe87865 on 2/6/2014 @ 11:22 AM *

[img]http://i3.photobucket.com/albums/y65/bigjoe87865/20140206_110338_zpsc5eaac9d.jpg[img]

https://zx14ninjaforum.com/messages.cfm?threadid=B41D3543-D56B-84E2-15BC1CF382C369AB

Do the mufflers and mid pipes separate?
Looks like a poor bend?
'Not best you know?'

Now you know!

yes they do separate, I have tried tweaking it around for a while and have not found the right angle. It either hits the chain, rear peg, front peg depending on the tweaking.

I am starting to believe it is poorly made. Unless the difference in headers could really throw it off that much. I have tried looking at pictures of 06 headers and mine look just like them. In-fact I couldn't tell the difference between an 06/07 and an 08+ headers when looking at pictures on ebay

I have a hard time believing that the tips should be angled out like that. Usually they point straight back. Something ain't right.

Mad

Do you try to install mid pipe at first , turn them right position and after that put mufflers ?

Those photos they are connected .

Looks like what I went through on my Busa, same angle and everything and it ended up being the wrong header just a couple mm off is all it takes. I would check your local dealer for the right part number to see if its the right header and go from there, if its right you got a bum set of slip-ons and should probably order a set of Muzzys! gotta kaw getta Muzz

Yeah the tips are supposed to be outward, check out this thread https://zx14ninjaforum.com/messages.cfm?threadid=B41D3543-D56B-84E2-15BC1CF382C369AB

I did install the midpipe first and turned it in the way that it would not touch the front pegs/chain/stand. Then added the mufflers. I have already packed up the mufflers and installed stock muffler back. gave up on it.

as far as the header part number, the only number I see is the KHI M 104 as seen in the pics

I have Boz Bros on my 2012 using the stock header that came from Kawasaki. I liked the street version so I also have the race version. Here is a picture of mine from the rear.

And from the side.

Make sure you have the mid pipes on the correct side. The pipe with the most bends goes on the left side of the bike. The fewer bends on the right side. The left side mid pipe when properly mounted is close to the chain but cant get any closer as the distance from the chain grows when weight is on the bike. Also, they are a great sounding pipe. Not too loud for my neighbors or the police but much better sounding than the stock pipes. You have the mufflers way to high on the bike and way to far away from the bike. Stick with it. You will figure it out. Or bring it over to my house in Missouri and I will install them for you! BTW I still have the installation instructions that came with the Boz Bros if you need them.

* Last updated by: streetracer on 2/6/2014 @ 5:21 PM *

Thanks streetracer!, you give me some hope now. but I still am not sure where I went wrong lol, I am using the one with 4 bends on the left side (chain side) and 2 bends on the right side)

Were your boz made for a 2012 zx14r or the first gen zx14? You did not need to do any modifications on your headers? Do they have cats on them? also, if you happen to know, are your stock 2012 headers pretty much the same as 08-11 zx14 headers? I noticed in your picture, it does not having the extra fairing on the bottom , I feel like your right side midpipe is longer as well. My mufflers dont go as far back as yours.

* Last updated by: bigjoe87865 on 2/6/2014 @ 6:10 PM *

If the midpipes slip onto the header, they are the correct year. '06-'07 header outlets are 51 mm diameter and '08-'11 are 53 mm to make up for the obstruction of the 3rd catalyst (bulge in the collector).

Thanks Danno, the mid pipes do slip in, but I figured it would slip into either headers because the 2mm difference is not great enough to block the mids from going in. They could just expand slightly to fit in right?.

and was concerned about whether or not this bulge is the cat or not. http://i3.photobucket.com/albums/y65/bigjoe87865/20140206_105847_zpsd3dc1b6a.jpg

Also in this picture you can see the midpipes fit on the header outlet, but they don't sit flush all the way in with the stop on the header outlet. Is it because they are the 53mm outlets?.
http://i3.photobucket.com/albums/y65/bigjoe87865/20140206_110523_zps8626d78a.jpg

Aside from header outlets size and the cat, are there any physical differences between the 06/07 and 08+ headers? Do they angle different as well?

and was concerned about whether or not this bulge is the cat or not.

Also in this picture you can see the midpipes fit on the header outlet, but they don't sit flush all the way in with the stop on the header outlet. Is it because they are the 53mm outlets?.

Aside from header outlets size and the cat, are there any physical differences between the 06/07 and 08+ headers? Do they angle different as well?

Hub has answered this one a kajillion times over the years. If he's still watching, he knows this. I do not remember the exact details but I am pretty sure the answer has to do with what gaskets you use between the collector and the midpipes. If you use the right gasket (probably the Gen2 gasket cuz it should be bigger?) the pipes should seal....if I remember correctly.

* Last updated by: Rook on 2/7/2014 @ 6:43 AM *

Were your boz made for a 2012 zx14r or the first gen zx14?

My Boz was made for the 06/07 ZX14.

You did not need to do any modifications on your headers? Do they have cats on them?

I had to modify the Boz mid pipe where it connects to the header as the 2012 header diameter was larger. No. the 2012 doesnt have cats in the header. They are in the mufflers.

also, if you happen to know, are your stock 2012 headers pretty much the same as 08-11 zx14 headers?

Sorry, but I dont know the answer.

I noticed in your picture, it does not having the extra fairing on the bottom , I feel like your right side midpipe is longer as well. My mufflers dont go as far back as yours.

I removed the bottom fairing for easier access to the shock and links. Cant comment on the length of the midpipe except to say it is the stock length from Boz. Boz had two different mufflers available. Street version 18 inch muffler and race version 15 inch muffler. The picture is the 18 inch version. You may have the 15 inch version.

* Last updated by: streetracer on 2/7/2014 @ 7:39 AM *

Thanks guys, Streetracer, yeah I have the race version so that is why mine is shorter.

Rook : I am going to search up hubs posts regarding header differences. If it is just the outlet diameter and not a different angle or length, then I should not have an issue with installation. Going to attempt it again today

BigJoe: Iron Pony had the "race" version on sale for $100 including shipping. I liked the "street" version so I bought the "race" version recently and didnt even have to change the mid pipes. They fit right on the existing mid pipes from the "street" version. The sound is great without being too loud. You will like it and so will your neighbors ! Giterdone !!!!

Bulb = A cleaver way to run duals out one header plus some.
Cat-Less Bulbs = 2006-2007 and 2012-2014.
Bulbs with Cat = 2008-2011.

Mid Gasket Differential:

Bulb's Gasket = Fat ~ would be a cat-less bulb, because there is no restriction but an empty bulb. First 2 years only.
Bulb w/Cat = Narrow ~ gasket happened when they expanded the headers/bulb/outlets so the honeycomb would not effect flow but break even [as if empty] with the expansion of the header/bulb/outlets.

Bulb Interchangeability:

2006-2011 = Use any 1st/2nd gen OE muffler to slip on any 1st/2nd gen bulb.
Gaskets = That change in "Gaskethickness" is the connection solver.

Generation Bulbs:

2006-7 = Smallest size are the header tubes and tip diameters.
2008-11 = Mid size grew in same mm growth for the honeycomb.
2012-14 = Biggest tip diameter grew for bore size change - No cat inside is my guess.

Just that one mm growth was enough to keep things from sliding into each other times 3 gens.

Aftmket Slips:

If say there is a parts number change for the same look of the slip, then they followed that slip as the gens changed. I'm an OE kind of guy so the slippers need to chime in and say, 'I kept my old slips and they slipped back on to the 2nd gen as well.' Now you know, or find the same part number on line, that answered that.

As far as the slips here, that looks like a nice tight fit to the bulb. The placing of the reversed pipe was an excellent variable. If we are still fit-less; stand both the stock muffler and slip next to each other; look at both mid pipe curves [at two angles] as you upright the muffler's brackets in the vertical and to the equal height in the horizontal and all that look me over.

I've never seen a configuration like Hubs there...that isn't a zx14 header there...right?There should be a flat around the midpipe/header fit...where you would use a band to assemble...yes?What are we looking at?Never seen that flange on any of mine.

ONE of those midpipes are wrong.Either turned wrong...or not made correctly.Where'd you say you got those?It should be clearing everything on both sides.My guess....the left side midpipe is not turned correctly....doesn't need to be off by much to get the results you're seeing.The diameters and all seem to be okay...you're able to fit the pipes into each other.Yes?The 06's and 07's DID have a gasket at the midpipe/header fitting.IDK about later models....should be the same deal.Only pipe fitment deal started on the 2012's....

* Last updated by: Grn14 on 2/7/2014 @ 11:12 AM *

streetracer, That is where I got it from lol, at that price I thought I couldn't go wrong.

Anyways, I tried again this time on only the right side, and no go, tried every which way to angle in the midpipe and exhaust and I gave up. maybe ill take it to someone or just return it

Anyways, regarding my stock exhaust, I have a feeling they are not from a 2006 , probably an 08+ since the previous owner installed them on the bike and I am pretty sure I have an 06 header. So when putting back the stock exhaust, I can't seem to get it to be nice and tight at the header outlet. Who ever installed the cans made some ghetto gasket out of very thin metal sheets rolled up. They are not holding up well anymore and my exhaust is loose and even leaks a little bit when the engine is running.

What kind of gasket or something of that sort can I buy to insert there and close up the gap between the diameter of my stock exhaust and the header outlet?

Bike bandit.com you can get the gasket or go to dealer and order what you need O.E.

Sounds like the header/midpipe 'gap' could be filled with a new Connie gasket.You have stock headers right?And you have the stock muffler(s)..yes?A factory gasket SHOULD fit.I don't know IF the 08's had a slightly larger diameter.That's the year Kawasaki did some upgrades to their zx14.(might have been only in the secondary opening program....IDK).There's a chance you could buy a set of gaskets for the Connie...(pre 2012).The Connie has a single exhaust...so you'd need TWO.The Connie gasket is thinner than the zx14's.

success finally! felt like a noob lol. This is the boz bros race exhaust and it sounds nice and deep. A tad on the loud side but bearable. at idle, it massages my ass. it has a drone below 3k when cruising in high gear. pops when de-accelerating. Over all I am happy and especially the price

The chain was awfully close, had to tighten my chain. Dont know why they would bend it that close to the chain. Streetracer, similar to yours?

----

GRN14, Thanks for the concours gasket tip. I have stock headers from an 06 and the diameter of the outlet is smaller than the 08+. amd my stock mufflers are most likely 08+ and they float on the 06 headers. If I ever decide to put the stockers back on, ill get some concours gasket

* Last updated by: bigjoe87865 on 2/8/2014 @ 12:22 PM *

Nice pics of your floor there brother;)You can edit those on your picture program(online) and change the size of the total picture area.PROBABLY down to say,600X450...something along those lines;)They're most likely at around 1000Xsomething right now.And also...you're welcome...glad your pipes fit up finally....IS the muffler oval?That one pics of the other bike...it looks oval...and some others look round.

Oops, sorry about that.. just resized them :) yes they are oval pipes