Document ID 996434
!
Page 1 of 9
!
!
!
!
!
!
Brock’s Performance • 4064 E. Patterson Road • Dayton, OH 45430 • Phone: 937-912-0054 • Fax: 937-912-0062
!
INSTALLATION INSTRUCTIONS FOR BROCK’S PERFORMANCE
ZX-14R (12-14) ALIEN HEAD 2™ OR SHORTMEG 2™ FULL EXHAUST SYSTEM
To View Installation Video: BrocksPerformance.com > Customer Service > Product Information > Installation Instructions
!
The Alien Head 2™ or ShortMeg 2™ for the ZX-14R (12-14) is a high performance 4-2-1 exhaust
system that replaces the stock headers, mid-pipes, and mufflers. It converts the stock dual-muffler
design into a single-sided muffler mounted on the right side of the bike.
STEP 1: Check Package Contents: The Alien Head 2™ or ShortMeg 2™ System is shown
(Figure 1). The package contents include:
1. Four Header Mounting Flanges
2. One Right Side And One Left Side Header
3. One Secondary Collector
4. One Mid-Pipe
5. Package Containing Springs, Spring Puller, and One Red PAIR Valve Block-Off Cap
6. One Alien Head 2™ or ShortMeg 2™ Muffler
7. One Tube of Permatex™ Ultra Copper® Sealant
8. One Packet Containing Instructions and Supplemental Information
If any parts are missing, please contact Brock’s Performance.
Figure 1
Document ID 996434
!
Page 2 of 9
Note: A slight ovaling of the tubing can occur during the manufacturing process, this is normal.
A twisting motion may be required during assembly/disassembly.
STEP 2: Pre-Assemble Headers, Collector, and Mid-Pipe to Ensure Proper Fit
Between All Parts: The pre-assembled system is shown (Figure 2). Pre-assembly helps to detect
any potential shipping damage and ensures that all parts fit properly. Apply WD-40® to the pipe joints
to ease assembly, adjustment, and especially disassembly.
Figure 2
Caution: During all steps below, the fairings should remove with ease. If you
feel resistance, stop and assess the situation before continuing.
STEP 3: Remove ZX-14R Dashboards: The dashboards are held in place by three fasteners
shown (Figure 3). Note that all dashboard and
fairing fasteners have thin plastic washers
located between the fastener head and the
plastic bodywork. Save the plastic washers to be
reused later. To avoid losing fasteners and
washers, it is recommended that the installer
place them in a container. With a two-handed
grip on the inside of the dashboard, gently pull
towards the forks to release the tabs holding the
dashboard in place. Lift the dashboard upwards
to remove.
Figure 3 ------------------------->
Document ID 996434
!
Page 3 of 9
STEP 4: Remove the Right and Left Fairing Grills:
• Remove fasteners and washers at positions 4, 5, and 6 (Figure 4) for the right side fairing grill.
• Note bolt tab on the fairing grill positioned under the tank cover at fastener 4, pull tank cover
away slightly to release tab. Dotted line shows locations of hidden tab (Figure 4).
• The fairing grill is now held in place by
two rubber snap grommets inserted into
the mid-fairing. Pull the fairing grill away
from the mid-fairing slightly and slide
fairing to the rear to remove. Yellow
circles show locations of hidden snap
grommets (Figure 4).
• Repeat for left fairing grill.
Figure 4 ------------------------->
Caution: When performing the steps below use extreme care when releasing
tank cover from side fairing grommets. The tab shown in (Figure 5 B) has
been known to break easily.
Figure 5 A Figure 5 B
STEP 5: Remove the Tank Cover: The tank cover is held in place by three fasteners (Figure 5
A). Fastener 7 is located on the right side, Fastener 8 on the left side, and Fastener 9 at the front of
the tank cover. Remove Fastener 9. The tank cover is now held in place by pins in snap grommets. Pull
the tank cover evenly in an outward direction on both sides to clear the grommets and hooks. Then lift
the tank cover to remove it from the bike frame.
Document ID 996434
!
Page 4 of 9
STEP 6: Remove Side Fairings: The locations of the bolts and quick rivets holding the fairings
in place are illustrated (Figure 6 A, B, C, D, & E). Details are provided below:
• A quick rivet is located in the lower nose of front fairing, behind the front tire, and holds the left and
right panels together. Using a thin blade screwdriver lift the center of the rivet head. Then pull the
rivet from the bodywork. This will release the right panel from the left panel.
• Remove the quick rivet at location 10 (Figure 6 A). Use a pin or small hex head wrench to push the
center of the quick rivet inward. Then remove the rivet using a small flat head screwdriver.
• Remove the 2 quick rivets at locations 11 and 12, next to the turn signal (Figure 6 B). Use a pin or
small hex head wrench to push the center of the quick rivet inward. Then remove the rivet using a
small flat head screwdriver.
• Remove the side fairing fasteners & washers at locations 13, 14, 15, & 16 (Figure 6 C) on the right
fairing panel.
• Remove the fastener at location 17 (Figure 6 D).
• The side fairing is now connected to the front nose fairing with only hooks and slots (Figure 6 E).
Gently slide the side fairing rearward to separate it from the front nose fairing.
• Note that the turn signal wiring is connected to the wiring harness using a quick disconnect. When
removing the mid-fairing take care not to damage the connector.
• Repeat for the left side lower fairing.
Figure 6 A Figure 6 B
Figure 6 C Figure 6 D
Document ID 996434
!
Page 5 of 9
Figure 6 E Figure 7
STEP 7: Remove the Stock Right and Left Muffler Bodies (Figure 7):
• Remove the belly pan by removing the 4 fasteners at location 18.
• Loosen the mid-pipe clamp at location 19.
• Remove the bolt at location 20.
• Remove the passenger rear foot peg bolt at location 21. This bolt will be reused on both sides to
secure the bushing.
• Pull the muffler body to the rear to release it from the collector.
• Left side removal is the same except there is no bolt at location 20.
STEP 8: Remove the Stock Header Assembly (Figure 8): The procedure described
below does not require removal of the radiator. However, the fit is tight, and care should be taken to
avoid damage to the radiator.
• Locate the lower radiator bracket that connects the radiator to the center of the engine block.
Remove the bolt (6 x 22mm) from the bracket supporting the lower portion of the radiator. This will
allow you to gently ease the radiator forward for additional clearance when removing the headers.
• Remove the header nuts. Use of an extension
will allow easier access to the header bolts.
There are two bolts per header tube. Once the
bolts are removed do not allow the header
flange to fall and contact the radiator.
Carefully move the flange to a position away
from the radiator.
• Once all bolts are removed, carefully remove
the header from the engine. Avoid contact
with the radiator.
Figure 8 ------------------------->
Document ID 996434
!
Page 6 of 9
STEP
9: INSTALL THE HEADER M OUNT FLANGES:
Note that the spring mounting tabs are oriented on the
bottom of the flange.
Install the four header mounting flanges and spigots
using the OEM nuts as shown (Figure 9). We also reuse
the OEM gaskets. 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 10: Install the Headers and Collector (Figure 10):
Install the right side header, left side header, and 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 as 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 head
pipes onto flanges as far as they will go, then connect the springs to spring tabs on the headers using
the spring puller supplied. ‘Wiggling’ the entire assembly with the springs installed will pull the pipes
into their final location.
Do not attach the springs holding the secondary
collector to the headers, yet. The following figure
shows the properly installed assembly. The
headers (22) are attached to the spigots by a
spring (23). There is a tight fit between the
bottom of the header assembly and the radiator
(24,) but the two parts should have adequate
clearance so that no contact is made. Adjust as
required.
Figure 10 ------------------------->
Document ID 996434
!
Page 7 of 9
STEP 11: Install the Mid- Pipe and Muffler (Figure 11)
• Slip the large diameter end of the mid-pipe onto the collector. Adjust as necessary to ensure that
the spring tabs align.
• Install the muffler onto the mid-pipe. Adjust as necessary to ensure that the mounting bracket lines
up with the OEM mounting location. Insert the OEM muffler-mounting bolt through the bracket on
the muffler and into the OEM mounting location (Location 28). Place the OEM washer then nut on
the bolt and tighten enough to hold the system in place. Do not fully tighten until final adjustments
have been made.
• Adjust the assembly by hand as required to
ensure proper clearance between the belly
pan and muffler, and then attach mount
springs at locations 25, 26, and 27. Torque
the muffler mount bolt at location 28 to
34 N-m or (25 ft-lb). Reattached the radiator
to the lower radiator bracket with the OEM
(6x22mm) bolt and torque to 9.8 Nm or
(87 in-lb).
• Re-install the fairings in the reverse order that
they were removed. (See Caution Below.)
Figure 11 ------------------------->
Caution: Failing to follow the steps below may result in
damage to your bike!
The right and left side fairing grills should be the last body panels installed, this will
allow you to reach in behind and support the tank cover tab identified in (Figure 5 B -
Page 3). Lubricate the rubber snap grommet. Using your finger support the backside
of the tab as you gently push the pin into the rubber snap grommet. After the tank
cover has been secured the side fairing grills can now be assembled in reverse order.
DO NOT START BIKE UNTIL FAIRINGS HAVE BEEN INSTALLED AND YOU HAVE
ENSURED A MINIMUM ¼-INCH CLEARANCE BETWEEN THE EXHAUST COMPONENTS
AND ALL BODYWORK.
Failure to ensure proper clearance may result in burned plastic. Brock’s Performance exhaust systems are
designed to provide appropriate clearances. If minimum clearances are not obtained, remove the springs on the
exhaust system and adjust until proper clearance is achieved. It is also recommended that the entire exhaust
system be wiped down with rubbing alcohol to remove oil and fingerprints before starting the bike. This will help
prevent tarnishing of the finish after the bike has been started and the exhaust is heated up.
Fastener Identification & Torque Specifications
Document ID 996434
!
Page 8 of 9
Any fastener that does not display a torque value does not have a factory torque
recommendation. These fasteners thread into rubber nut wells or have plastic washers that
will be damaged if over tightened. Always check fasteners for proper tightness as part of your
pre-ride inspection.
Location
Fastener
Torque
Description
Tool
1 - Fig. 3
M5 x 16mm
Do Not Over Tighten
Black Dashboard Bolt
4mm Hex Wrench
2 - Fig. 3
M5 x 16mm
Do Not Over Tighten
Black Dashboard Bolt
4mm Hex Wrench
3 - Fig. 3
M5 x 16mm
Do Not Over Tighten
Black Dashboard Bolt
4mm Hex Wrench
4 - Fig. 4
M6 x 30mm
Do Not Over Tighten
Stainless Fairing Grill Bolt
5mm Hex Wrench
5 - Fig. 4
M6 x 14mm
Do Not Over Tighten
Stainless Fairing Grill Bolt
5mm Hex Wrench
6 - Fig. 4
M5 x 20mm
Do Not Over Tighten
Black Fairing Grill Bolt
4mm Hex Wrench
7 - Fig. 5A
M6 x 30mm
Do Not Over Tighten
Stainless Tank Cover Bolt
5mm Hex Wrench
8 - Fig. 5A
M6 x 30mm
Do Not Over Tighten
Stainless Tank Cover Bolt
5mm Hex Wrench
9 - Fig. 5A
M6 x 23mm
Do Not Over Tighten
Stainless Tank Cover Bolt
5mm Hex Wrench
10 - Fig. 6A
Quick Rivet
N/A
Black Rivet 12mm Head DIA.
Small DIA. Screwdriver
11 - Fig. 6B
Quick Rivet
N/A
Black Rivet 11mm Head DIA.
Small DIA. Screwdriver
12 - Fig. 6B
Quick Rivet
N/A
Black Rivet 10mm head DIA.
Small DIA. Screwdriver
13 - Fig. 6C
M6 x 14mm
Do Not Over Tighten
Stainless Side Fairing Bolt
5mm Hex Wrench
14 - Fig. 6C
M6 x 14mm
Do Not Over Tighten
Stainless Side Fairing Bolt
5mm Hex Wrench
15 - Fig. 6C
M6 x 14mm
Do Not Over Tighten
Stainless Side Fairing Bolt
5mm Hex Wrench
16 - Fig. 6C
M6 x 14mm
Do Not Over Tighten
Stainless Side Fairing Bolt
5mm Hex Wrench
17 - Fig. 6D
M5 x 16mm
Do Not Over Tighten
Stainless Side Fairing Bolt
4mm Hex Wrench
18 - Fig. 7
M6 x 23mm
Do Not Over Tighten
Stainless Belly Pan Bolt
5mm Hex Wrench
19 - Fig. 7
Clamp Bolt
Do Not Over Tighten
Muffler Clamp Bolt
12mm Socket
20 - Fig. 7
M10 x 60mm
34 Nm (25 ft-lb)
Stainless Muffler Hanger Bolt
6mm Hex
Wrench/14mm Wrench
21 - Fig. 7
M10 x 60mm
34 Nm (25 ft-lb)
Stainless Muffler Hanger Bolt
6mm Hex
Wrench/14mm Wrench
22 - Fig. 10
Headers
N/A
N/A
N/A
23 - Fig. 10
Spring
N/A
N/A
Spring Puller
24 - Fig. 10
Clearance
N/A
N/A
N/A
25 - Fig. 11
Spring
N/A
N/A
Spring Puller
26 - Fig. 11
Spring
N/A
N/A
Spring Puller
27 - Fig. 11
Spring
N/A
N/A
Spring Puller
28 - Fig. 11
M10 x 60mm
34 Nm (25 ft-lb)
Stainless Muffler Hanger Bolt
6mm Hex
Wrench/14mm Wrench
N/A - Fig. 8
M6 x 22mm
9.8 Nm (87 in-lb)
Stainless Radiator Bolt
10mm Socket
Document ID 996434
!
Page 9 of 9
Print to scale for best results.
CONGRATULATIONS! INSTALLATION IS COMPLETE.
All Brock’s Performance products are designed for closed-course racetrack use ONLY!
For more information on Brock’s Performance Warranty and Terms and Conditions:
www.BrocksPerformance.com
> About Us > Terms and Conditions
For Questions and Comments:
www.BrocksPerformance.com > Customer Service > Contact Us
or call the Tech Line 937-912-0054
Loading...