Did you flatten out the top of the valve covers? It looks like the valve covers are flat and fit flush with the cowling in your pictures. Mine fits fine with the valve covers removed, but when reinstalled, the protrusions on the top of the valve covers are hitting the cowling. What type of exhaust are you planning on using? I have a Kelo exhaust, which would make a "cleaner" installation, but the short stacks would be more scale. I have had the Zero for probably three years, but have not done anything with it, but have a 1400mm FMS Zero on the way so thought that it is time to get it started .

Ken