I just recently bought a thunder blue 04 zx6r (yay for me) and have been recently fixing a slew of problems with it. I found that the mid pipe (on the end it connects to the header) was leaking. The exhaust is an aluminummuzzy slip on. So I tried to fix it but the clamp would not go tight enough to squeeze it. I found this to be no big deal because I found a oval carbon muzzy locally for $100 bucks. I tried to install it tonight and it has the SAME PROBLEM!!! I feel this is somthing stupid that I'm over looking. Mid-pipe on header, tighten clamp, 5mm of clearance all the way around!?!? Some help would be greatly appreciated. Thank you.

 

Congrats on your new ride. What you probably need is called a tail pipe expander.Sounds likethe pipe has been clamped too far for it to seal. Looks like this. http://www.harborfreight.com/cpi/cta...emnumber=37354

 

Or you can but a new titanium (sp?) mide pipe for around $60.

 

Is it a 636 or a ZZR600? You may have bought a Slip-On from a different model. 5mm is a lot of clearance all the way around.

 

Okay, well both midpipes are the correct piece. I used my expander which did not do very much due to the guage of the header pipe, and my other parts are going to be here tomorrow and I want to start riding again so a new pipe right now is really not my favorite choice. I know there is somthing extremely stupid that I am overlooking. Does anyone here have a Muzzy on an 03-04 that they would be willing to take a picture of the header to mid-pipe connection. Sorry for the rambling, this is very frustrating.


P.S. Also tried a U-Bolt clamp for car mufflers, worked better but still leaks and doesn't clear fairing.

 

does it have the gasket in it ?

 

 

11061 is what im refering to and az has a 04 or 03 with a tie muzzy on it.

 

NO IT DOES NOT! DUH!!! I knew it was the most simple overlooked thing. Excuse the dumb question. I am an automotive technician and have never worked on bikes. I wonder what the previous owner did with that gasket? (kid was a hack, twisted wires and electrical tape everywhere). Well thank you, now it's a matter of finding one locally. Does anyone know what bikes use the same gasket?

 

Don't feel stupid; that's why we're here! Unlike the previous owner, you took it upon yourself to find out how to do the job correctly, rather than hack it up (as it sounds like he did with the electrical system.) I'd take a look at that if I were you; don't want to see you be stranded somewhere. []

Hope your pipe is "right" soon!