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General Category >> Rubber Side Down! >> Aftermarket Exhaust install dilema
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Message started by necropsy on 01/28/06 at 14:33:29

Title: Aftermarket Exhaust install dilema
Post by necropsy on 01/28/06 at 14:33:29

The aftermarket exhaust I bought off of Ebay recently for $0.99, mated up to the S40 header perfectly and lays nice against the stock bracket.
http://bikepics.com/pics/pics/suzuki-boulevards40-05-bikepics-510943.jpg
Best of all, it sounds totally savage now. The only problem is, the tail end of the exhaust interferes with the brake cable.
http://bikepics.com/pics/pics/suzuki-boulevards40-05-bikepics-510941.jpg
I was wondering if any of you think I might get away with using a 1" cable sheath to prevent wear againt the muffler. My only other option is to get a 7.5" adapter with a ten degree bend and mount it further down the muffler bracket. This would also require bending the 1/4 " thick bracket on the exhaust, which I tried but wasn't happening.

Title: Re: Aftermarket Exhaust install dilema
Post by Dynobob on 01/28/06 at 14:56:33

That'll never do. Get that short adapter with the 10 degree bend in it made at the muffler shop. You need to make an adapter for the mount.

Title: Re: Aftermarket Exhaust install dilema
Post by SeeAPierce on 01/29/06 at 12:04:08

Yup - do the 10 degree adapter thing and all will be well!

http://suzukisavage.com/cgi-bin/YaBB.pl?board=RubberSideDown;action=display;num=1137701496;start=0#6

Title: Re: Aftermarket Exhaust install dilema
Post by necropsy on 01/30/06 at 12:16:35

Thanks for the replys, but since no one had any reasons why not, I think I'm just going to go ahead and do it.
I'll probably mount the sheath to the swing arm, and watch that it still moves freely. A little lithium grease every once and a while and all should be good.

Title: Re: Aftermarket Exhaust install dilema
Post by SAMM on 01/30/06 at 12:53:18

All that exaust and heat on my brake... and frame as well as freying my brake cable....Not me !!! The heat will damage the coating on the brake hub and look like %^&* after awile too.... Come on do the 10% pipe bend !!

Title: Re: Aftermarket Exhaust install dilema
Post by necropsy on 01/30/06 at 14:53:43

Ah, there we go. That's more like it. I've never taken NO!! for an answer. Not with out some sort of logic atleast. While I'm pretty sure the sheath set-up I'm working on would eliminate fraying, I hadn't really thought about the excess heat on the brake drum hub.
I'll have to have a closer look at that issue. I'm well aware that the 10 degree adapter would eliminate these issues, but creates a whole new set of issues, most notably the mounting nitemare that would create, and to a lesser degree, the overall appearance of having some ugly adapter in there.

Title: Re: Aftermarket Exhaust install dilema
Post by Dynobob on 01/30/06 at 16:42:19

necropsy wrote:

...and to a lesser degree, the overall appearance of having some ugly adapter in there.

You need to buy a short chrome heat shield to cover the juncture. You'll spend more time creating protection for the swingarm and cable than it would have taken to do it right. If your muffler saws through the brake cable you'll have a dangerous situation on your hands. It really isn't all that difficult.

Title: Re: Aftermarket Exhaust install dilema
Post by SeeAPierce on 01/31/06 at 13:15:14

Dynobob is spot on.

With a bit of work and an inexpensive heat shield you can have a great looking AND safe setup without clearance or heat problems. Go the extra mile and keep your ride worry-free... ;D

Title: Re: Aftermarket Exhaust install dilema
Post by necropsy on 01/31/06 at 15:19:24

thanks guys, :-[
I knew it was wrong in the first place, otherwise I wouldn't have asked. Any one tried bending the stock header? I'm assuming that would make a real mess of the chrome. I really don't want to hide that header to muffler connection. It gives me a stiffy just looking at it. :o

Title: Re: Aftermarket Exhaust install dilema
Post by SeeAPierce on 01/31/06 at 19:36:54

necropsy wrote:

A "stiffy"? That's a good thing isn't it? :D I'm telling ya dude, I wouldn't bend the header...get the adapter...IMHO...

I don't think it looks all that bad - maybe even good! ;)
http://members.aol.com/seeapierce/miscjunk/s40sport.jpg

Title: Re: Aftermarket Exhaust install dilema
Post by Savage_Rob on 01/31/06 at 20:19:12

I agree. I have the MAC on mine and it already has the bend in it but I also have a Sportster muffler I want to try out for fun. I'll be having the adaptor made when I do.

Title: Re: Aftermarket Exhaust install dilema
Post by Dynobob on 01/31/06 at 20:54:02

necropsy wrote:

Any one tried bending the stock header? I'm assuming that would make a real mess of the chrome.

Yes, it would mess up the chrome. Besides the header pipe is very thick (multiple layers) and you wouldn't be able to bend it without some serious equipment or an oxy acetelene torch.

Quote:

I really don't want to hide that header to muffler connection. It gives me a stiffy just looking at it.

HUH ???

Ok, let's put it another way ::) A nice heat shield will keep you from toasting your boots, pants, or leathers.