Alright, so my Gen 3 Streetsmart system showed up and I decide to install it tonight. Everything is going smooth until I try to place the headers into the header collector. It is waaaaaaaaaaaaaayyyy too tight! The headers slipped onto the flanges fine and the midpipe slides onto the collector fine. But the headers and header collector isn't going more than a 1/2 inch (and that's with a lot of work).

Anyone else have this problem? Is there a lube I could use? I gotta get back out there and ride and the bike sitting in the garage all tore down ain't cool!

Make sure you have everything in the correct order. When I installed the exhausts on both my ZX-12r and my ZX-14. The first time I tried it things did not quit fit right. Turned out I had a couple of the pipes in wrong. I've never installed a Gem 3, but that's the first thing I'd check.

When I put mine on everything fit perfect. I presume you pre fit things before you tried to install?? If things are truly out of whack you need to call Brocks. You may have a missmatch from another system they sell.

Yea, that doesn't sound right, those are supposed to be able to move around a bit as they heat up, expand and contract. I would pull 'em back off and see if the tube ID and OD finish are correct, if so then you might have a couple of the headers in the wrong postion. You can use a ceramic high temperature assembly lube when slipping every thing together so they don't seize up over time but they should slip fit without the lube when new. I got a tube of the stuff with my Akra pipe.

Painterdude, did Rook ever get ahold of you? I know he was looking for you awhile back.

Thanks for the feedback guys. I busted out the WD40 and twisted and worked the pipes and finally everything went together. It really was a little too tight but I got it to work.

BTW, I took the naked bike out for a spin and I gotta say there's a huge difference, even without the map installed! Can't wait to button everything up and get the map installed. Man i love this bike!