Suzuki Club UK

Did some more work on the sj today, got the 1.6 8v mounted in and tried to get the exhaust bolted up but it doesn't seem to fit.

It's (im guessing) a janspeed 4-2-1 exhaust that I bought for the 1.3 that fitted fine but on the 1.6 it's hitting the back off the engine where the engine bolts to the adaptor plate.

Anyone ever had this problem before?

how close is it? can always just knock a dent in the tube that's in the way.....It will not affect the performance.

Out of interest I just watched this whole video haha, you should see their test dents!

Exhaust Header Bash! Testing Power Loss From Dents Video


Click Here for Youtube Video



Bash away with gay abandon

It would need a good 15mm dent at least and it would be right on the joint where she goes from 2 to 1.

I've acquired another 4-2-1 manifold that I think has come off a 1.6 so I'm hoping should fit, it's also wider diameter tubing, she just needs a bit of welding which will be done tomorrow.

I just wasn't expecting it not to fit, they must have made different manifolds for the 1.6 and 1.3.

Anyway I got the 1.6 started today, seems to be running nice, excited now to get her back on the road!

Great video Sherwood, just watched it, might give the manifold a bashing tomorrow now

I love watching David Freiburger

There’s always the option of slitting the headers to bend them out and then welding them back up to gain the clearance needed. Won’t be too hard to do.

Well I tried the other exhaust and that also didn't fit, same thing hitting the back of the engine.

So I bashed my exhaust in slightly and also usee two manifold gaskets to bring it out little bit further.

I got her running and took her for a test drive and made the fatal mistake of not tightening up the sump plug. She dumped her oil in the road on the way back, luckily only 100 yards away. That's £20 worth of oil down the drain I'm really just happy no damage occurred to the engine.