Brocks Performance Alien Head 2 Full System 14" Muffler ZX-10R (11-14) - Manual (Page 5)

Document ID 993210
Page 5 of 7
STEP 7: Install the Header-Mounting Flanges:
Install the four header-mounting flanges in the orientation shown (Figure 9*) reusing the OEM nuts
and gaskets. Note: The #1 header flange must be installed with the spring tabs on top, which will be
opposite of the other three header flange positions with spring tabs on the bottom. Only 1 spring will
be used for each header tube, spring locations shown (Figure 9*).
*Note: View in figure 9 is shown as if you were standing in front of the bike looking at the engine.
Do not completely tighten the nuts. Leaving them
finger tight will allow easier adjustment when the
header pipes are fitted. The nuts will be fully
tightened after the header pipes are installed.
Figure 9 ------------------------->
STEP 8: Install the Header and
Collector Assembly:
Install the right-side header, left-side header, and then secondary collector. With header assembly now
installed onto the mounting flanges, tighten the mounting flange nuts enough to keep the flanges from
moving. Remove the header assembly and torque the flange nuts. Do not over tighten. Max
recommended torque is 10 ft-lb. Now attach the springs to the header mounting flanges in the
positions shown (Figure 9).
Prior to final installation of the headers, apply a very thin layer of Permatex™ Ultra Copper® to the
inside of each head pipe, no further than ½” into the pipe. This will ensure a high temperature seal is
created. Be careful to avoid contact with the
radiator while installing the header pipes. Install
header pipes onto flanges as far as they will go,
then connect the springs to spring tabs on the
headers using the supplied spring puller (Figure
10). ‘Wiggling’ the entire assembly with the
springs installed will pull the pipes into their final
location.
Figure 10 ------------------------->
Install the smaller bracket in place of where the
catalytic converter used to be held using the
supplied M8 x 70mm bolt (Figure 11 & 12). Once
this bracket is installed the collector will mount to
this bracket. Install the secondary collector onto to the header pipes. Use the spacer provided in the kit
to place between the collector mounting tab and the bracket, mount using the supplied M8 x 35mm
bolt (Figure 11 & 12). Hand-tighten the collector to the mounting bracket for now. The following
figures show the properly installed assembly. Attach the springs holding the secondary collector to the
headers. There is a tight fit between the bottom of the header assembly and the oil filter but the two
parts should have adequate clearance so that no contact is made. Adjust as required.