Oh and port matching a header on a 80 horse engine just ain't worth it and will not matter or you will not feel it. I would get whatever header has good reviews probably the Thorley or Calmini. I got the Thorley cause Summit has it and they have it now and are reliable.

I think what Zaggy was referring to is that the Zuk has square ports and some lesser brands of header just use round tubing. That kind of difference will be noticable, even at 80bhp

Hello again

1) When I said make sure the ports match...it's because some header mfg's are selling round
 Ã‚   port headers to fit a square exhaust port...(IMHO)waste of money.
2) I'm along ways from being a rich race car driver, good header wrap properly installed is
 Ã‚   cheap, been on my experimental engines 4 years (same header, different engines), wifes
 Ã‚   kick 3 years, no sign of deterioration on the wrap or header.
3) Low hp engines tend to respond better to initial intake and exhaust mods than you would
 Ã‚   think. It doesn't matter what 4 cycle engine you are dealing with, good exhaust and intake
 Ã‚   breathing makes a difference. Besides when you start with not much a little makes a huge
 Ã‚   difference. Not just my experience, check around the forum those that are doing the mods
 Ã‚   report only great results. Dyno testing backs it up.

 Ã‚   Hope you sort out the problems on your engine.

Zag

As far as my overall comments....

     I was giving some good, general advice to help the large number of "newbies" that have recently joined, as well as to remind those that have been around awhile what it's like to be new. I wasn't lecturing or talking down to anyone...just advising

    The comments were put there in a good spirit to keep this a friendly place.

As far as my knowledge on engines...check the forum

Zag

Thanks for you input Rhinoman

Zag

Your engine building knowledge far exceeds mine for sure. I have read everything you have ever written. I just don't think the round port header versus the square/oval head ports is really going to matter much when the round ports circle the entire square/oval ports. I could see a problem if the round ports were smaller but not when they are larger.
 Ã‚        All that being said I wanted the Calmini header but couldn't get a firm timeline I would get it. I wanted it for the coating and the position of the O2 bung but I must say the quality of the Thorley header is excellent!! Really thick flange and nice reducer with thick flange. It is kinda too purty for me though. I should have painted it flat black. I am working on an add on heat shield right nowso you will not be able to see it anyways.
 Ã‚        I have read about header wrap and seen it used alot and always when it was used the header was junk in short order. Thorley voids the warranty if you use it. But maybe it was used wrong alot so they are covering themselves. I never read anything good about it on a daily driver.

Maybe wrap is just bad here in the Midwest with rain,snow and salt treatments on the roads in the winter?

The port issue is a big deal (IMHO)....

     Incorrect or oversize ports can cause unnecessary turbulence in the primary tube, oversize round on a square often creates additional problems from creating pockets of vacum in the corners.
     This can in some cases actually increase back pressure, reduce flow and COST horsepower and decrease fuel mileage. Not to mention problems with getting a good gasket seal. My personal opinion and advice, if you have a square port put on a manifold that has a square port.
     Quality header wrap, like any other tool, used properly can be great, used wrong can be a problem...same with any add on.

Zag

You would know better than me. Sorry I spoke out of turn I can admit when I am wrong . I still don't think for the average person it is worth installing a header and 2 inch exhaust but if you are going to do it take the advice of people who know and get the Calmini header and do it right. The Thorley is a nice piece but to really do it right I think you must buy the Calmini.

IMHO

     I don't think brand is as important as quality and fit. I've never seen a Thorley header for a Suzuki, can't tell you if it's good, bad or indifferent...if it's as good as their Small block Chevy headers that I've used it's probly fine.
     I bought Calmini last time because it was the only header I could see a good pic of. No one up here stocks headers for Suzuki and I couldn't find a pic of any of the others. I don't like messing around so I bought the Calmini because I could see what I was getting before ordering (immediately cut it up once I got it but that's another story).
     I believe that a a manifold should at least be the shape of the port I'm putting it on, everything I've read over the years has taught me that.

As far as being right or wrong that's never the issue, it's the exchange of information that is.

      FWIW I don't believe there is such a thing as speaking out of turn. Mind you I also don't believe there is such a thing as a dumb question only dumb answer.

Opinions are like belly buttons...everybody has got one.

     As far as your unit...from what you have posted, theres a problem of some kind, I believe you will be much happier with both your Zuk and your header/exhaust install when you have got it fixed.

     Wish I could tell you what's wrong but without seeing it I don't know.

Thanks

Zag