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Message started by toddlamp8 on 11/09/07 at 21:39:37

Title: Why won't my MAC exhaust fit??
Post by toddlamp8 on 11/09/07 at 21:39:37

I ordered a MAC slip-on exhaust from Dennis Kirk thinking it was going to be an easy install since it's made for the bike right? Wrong, I am having nothing but trouble! There are no instructions (not that I thought I would need them) and while the pipe fits, it appears that the openning is WAY to big (even with the copper gasket) and so when I tighten the POS clamp that was included, the metal starts to fold and I end up with this:
http://www.toddlampone.com/pictures/motorcycles/ls650/images/DSC03453.jpg

http://www.toddlampone.com/pictures/motorcycles/ls650/images/DSC03454.jpg

What is going on?

Title: Re: Why won't my MAC exhaust fit??
Post by barry68v10 on 11/10/07 at 03:46:58

It looks like the MAC is 1/8" too big. What size does it say it is? You can get reducers called muffler spacers or muffler adapters I forget which...anyway I think they come in 1 3/4", 1 5/8", and 1 1/2"...

Title: Re: Why won't my MAC exhaust fit??
Post by ls650v on 11/10/07 at 05:34:41

Maybe the MAC should use the gasket that goes between the stock exhaust and header pipe? That would account for about 1/8 inch.

Title: Re: Why won't my MAC exhaust fit??
Post by toddlamp8 on 11/10/07 at 07:44:39

It is using the stock gasket. That's what the circular part is in the center. I w ill be calling dennis kirk today.

Title: Re: Why won't my MAC exhaust fit??
Post by Savage_Greg on 11/10/07 at 09:35:51

Not really familiar with the Mac, but isn't there some slots in that flared end?

Seems like that would allow the pipe to tighten up...

...might be looking at it wrong too...???

Title: Re: Why won't my MAC exhaust fit??
Post by toddlamp8 on 11/10/07 at 10:09:44

Savage_Greg wrote:

Not really familiar with the Mac, but isn't there some slots in that flared end?

Seems like that would allow the pipe to tighten up...

...might be looking at it wrong too...???

There was one ~1/2" slot. I cut 2 more thinking that would help but obviously it didn't. It's pretty loose on there even with it clamped down all the way.

Title: Re: Why won't my MAC exhaust fit??
Post by bill67 on 11/10/07 at 10:26:11

Was that muffler for the savage? If it was i would call them and tell them.

Title: Re: Why won't my MAC exhaust fit??
Post by vtail on 11/10/07 at 10:46:13

Toddlamp8.Don't panick I'm busy but I'll be back on line to explain what you're doing wrong in 20 minutues.

Title: Re: Why won't my MAC exhaust fit??
Post by toddlamp8 on 11/10/07 at 11:01:18

It's been 30 mins ;)

Please tell me what i'm doing wrong because I feel like I have tryed everything I can.

Title: Re: Why won't my MAC exhaust fit??
Post by vtail on 11/10/07 at 11:17:00

Oke, First take that wrinkle out off the Mac. Clamp a dowel (like a broomstick) in a vice and slide Mac on to it. Lightly tap out wrinkle. Now create 2 more slits with a hacksaw ( I think you already did this)so that you have a total of 4 slits. ( at 90,180,270,360 degrees).
You shouls have 4 tabs on the Mac where it slips onto the headerpipe.Bend these tabs out very slightly for ease of slipping it on to the header. Put clamp on Mac (very loose). Now take the factory gasket (((which on your picture is WAY deep (wrong)) into your Mac))) and slip it on the HEADERPIPE till the STOP (Big ridge). Slip on MAC over gasket till the same STOP. DO NOT SLIDE MAC OVER THIS STOP! You should be able to see the gasket trough the slits. If the gasket doesn't cover the slits all the way use a LITTLE high temp sealer. Slide clamp forward over slits and tighten. The clamp should be clamped over the slits with the gasket underneath, since this gasket is also your SPACER. Make sure the most rear muffler bolt (where it bolts onto the carrier)has the supplied spacer to raise the mac up a bit. ;)

Title: Re: Why won't my MAC exhaust fit??
Post by toddlamp8 on 11/10/07 at 11:28:25

Thanks for the write-up but I tried that already. In fact that was how I initially did it. The only thing I haven't done was to put a 4th slit into the exhaust. I didn't even have to bend out the tabs to get it on. It went on very easily, too easily.

Title: Re: Why won't my MAC exhaust fit??
Post by toddlamp8 on 11/10/07 at 11:29:43

I think tonight I will put a bunch of slits in it and try again.

Title: Re: Why won't my MAC exhaust fit??
Post by Paladin on 11/10/07 at 11:34:01

vtail wrote:

I would appreciate it if you copy this into the TECH section so I can find it next year.

Title: Re: Why won't my MAC exhaust fit??
Post by vtail on 11/10/07 at 11:39:22

NO,NO. No need. The factory gasket on my '07 was a rather thick grey one, and therefore it's a spacer too. The gasket needs to be inside your Mac , flush with the front (not deep inside) and covering the slits. That's also where the clamp goes. But install gasket on headerpipe FIRST than slip on the Mac. Make sure the mac is against the stop-ring on the headerpipe :) And yes if the gasket/spacer is deeper inside your Mac, you will pinch it like in your pics :)

Title: Re: Why won't my MAC exhaust fit??
Post by vtail on 11/10/07 at 11:44:32

Paladin, consider it done ;)

Title: Re: Why won't my MAC exhaust fit??
Post by toddlamp8 on 11/10/07 at 15:42:36

vtail wrote:

I understand what you're saying and that's the way that I did it in the first place. the gasket that I ahve a a solid copper ring. This way did NOT work. There is too much space between the muffler and the gasket. Even with the gasket in place there is still no need to bend the tabs outward because there is still a lot of space.

Title: Re: Why won't my MAC exhaust fit??
Post by vtail on 11/10/07 at 16:38:35

My stock gasket is a thick soft paper/cloth? material that when handled gets your finger all grey, like it has lead in it. Did you get your bike new? If not, some previous owner might have used that copper ring. You could wrap that ring with aluminum tape till you have the proper thickness. In other words, where the Mac almost goes on with a little friction. Wish you luck. ;)

Title: Re: Why won't my MAC exhaust fit??
Post by toddlamp8 on 11/10/07 at 19:55:51

Thanks. There was a gasket similar to what you mentioned on the exhaust when I took the stock muffler off. It was damaged in the process so I went to order one from the Suzuki dealer. The one that I wanted was superceeded by a new part number and that was the one that was ordered. He said that I could not get the original one. I also looked at RonAyers.com and they had a new part number as well.

What aluminum tape are you referring to? I am going to call Dennins Kirk's technical support on Monday but until then I'd like to try whatever I can.

Title: Re: Why won't my MAC exhaust fit??
Post by thumperclone on 11/10/07 at 21:49:35

ive used aluminum cans and even plumbers staping in similar cases along with a good dose of rtv..

Title: Re: Why won't my MAC exhaust fit??
Post by Savage_Rob on 11/11/07 at 13:26:14

There are two types of gaskets: one is copper jacketed and the other is just an impregnated fiber type. The copper type will not deform easily enough to work well with the MAC. The fiber type will.

Title: Re: Why won't my MAC exhaust fit??
Post by toddlamp8 on 11/11/07 at 13:48:21

Savage_Rob wrote:

There are two types of gaskets: one is copper jacketed and the other is just an impregnated fiber type. The copper type will not deform easily enough to work well with the MAC. The fiber type will.

How can I get the fiber type then? It's a discontinued part.

Is the fiber type thicker than the copper type? I don't think the deformation characteristics of the gasket have much to do with compatibility. It's the thickness that I need. Something to take up more space

Title: Re: Why won't my MAC exhaust fit??
Post by Savage_Rob on 11/11/07 at 14:00:55

toddlamp8 wrote:

Seems line RonAyers had both types. They were about the same dimensions. I actually had to shave mine down a bit to get the MAC on properly. Now that it's on and never leaks. I don't take it off. I remove header and muffler as a single unit these days.

Title: Re: Why won't my MAC exhaust fit??
Post by toddlamp8 on 11/12/07 at 16:27:14

Which MAC pipe did you order? If you're using the MAC pipe with the copper gasket than something is wrong with the one I have.

Title: Re: Why won't my MAC exhaust fit??
Post by vtail on 11/12/07 at 16:39:16

There's only one Mac muffler for the S(avage)40. The gasket used should be the origional fiber type. My Mac didn't come with any gasket, I managed to pry out the fiber one and re-use it. :)

Title: Re: Why won't my MAC exhaust fit??
Post by toddlamp8 on 11/12/07 at 19:41:11

My MAC didn't come with a gasket either. I went to buy the fiber one but it has been superceeded by the new copper gasket so I couldn't get it. My original gasket was hacked up when I took the stock muffler on.

Anyway... After some aluminum tape and a heaping amount of Muffler Mender, it's on. It sounds GLORIOUS! It was worth the trouble.