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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Exhaust doesn't line up /cgi-bin/YaBB.pl?num=1242698227 Message started by DrunkenDwarf on 05/18/09 at 18:57:07 |
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Title: Exhaust doesn't line up Post by DrunkenDwarf on 05/18/09 at 18:57:07 I finally pulled the heat shield off to see what's going on between the header and the muffler. It doesn't line up. Here's some pictures. http://picasaweb.google.com/mdahrea/Muffler?authkey=Gv1sRgCOrI5KKr5ubRIQ&feat=directlink It's a Harley Davidson Dyna Super Glide muffler that the previous owner installed. It looks like the stock muffler has a little bend in it where it attaches to the header. Is this typical? How have others solved this? -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by serowbot on 05/18/09 at 22:25:27 That looks a little loose to me.... could be leaking air, almost certainly really..... If you want to put in the effort,... work it till you get a tighter fit. A little drillin', schoochin', twistin',... mine butts up tight to the header-stop,... less angle, and no leaks. I put it on and off about 5 times.... no easy ways or shortcuts,... You just gotta' get determined... If it bothers you,... you'll put in the effort... If it don't, you won't... some of us are wrenchers.. some of us are riders.. some of us are both... Some of us will give you better advice... I just bumped you... Peace ;D |
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Title: Re: Exhaust doesn't line up Post by marshall13 on 05/18/09 at 22:42:23 ok, the damage is actually the evidence of somebody grabbing the muff while it's hot(the tan is oil, the purple is glove tips or fingers)... those are fingerprints, kind of...lol what it looks like is you need a longer mounting rail... the bolt is to the end of the slot, and the muff is an inch shy of the end of the adaptor... easiest fix is a 1 3/4 inch male to female adaptor pipe, available at any autoparts store... remove the muff completely, tap the adaptors female end on the headpipe... hang 2 clamps on the adaptor... run the muff onto the end of the adaptor(may have to trim either or both ends of the adaptor), line up the hanger and install the bolt finger tight... then tighten front to back... adaptor to headpipe clamp, muff to adaptor clamp, then mounting bolt.... you can get a muffler shop to make you the adaptor, and put in the 7 degree bend to angle the rear out away from your brake...(it gets soot on the retaining rod).... a muff shop can fab it in stainless too... |
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Title: Re: Exhaust doesn't line up Post by matt on 05/19/09 at 10:59:22 i bet that casued some extra backfires 2533243921343922560 wrote:
I have a supertrapp i had to wrestle with to get on, i eventually got it. Next time i needed to remove and re-install i just removed the whole pipe lol. I made changes, finger tighten two pipes together, install on bike, align ALL the screws (header and bracket at end) and finger tight before you wrench them down. I hear there is some kinda tape or material you can put inbween the connectors to get real good airtight seal. Is there such a thing in existance? worth it all? |
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Title: Re: Exhaust doesn't line up Post by PTRider on 05/19/09 at 12:53:30 Walker Acousti/seal Exhaust System Sealing Compound (http://coolcatcorp.com/Merchant2/merchant.mvc?Screen=PROD&Product_Code=Sealer&Category_Code=Exhaust) or an equivalent product from another company at a good auto parts store near you. |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/19/09 at 13:27:27 Anybody know if this muffler and header are the same diameter? http://cgi.ebay.com/ebaymotors/SUZUKI-SAVAGE-LS650-1-3-4-INCH-MUFFLER-REDUCER-SLEEVE_W0QQcmdZViewItemQQcategoryZ35596QQihZ005QQitemZ150340962513QQrdZ1QQsspagenameZWDVW Found a reducer sleeve on Ebay (I'm sure Advance Auto has something). I don't know if it's required or not. -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/19/09 at 17:05:42 Quote:
It's not about will, it's about knowledge. The problem is I'm ignorant. I can take the muffler off and put it back on, but that doesn't address the issue of making it stay. I guess I could just nail it to the header. -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/19/09 at 18:17:29 I apologize for the triple post. Screwed around with it some more. Added a couple more pictures. The muffler slips right on. There's about 1/16 inch free play between the muffler and the header. It just rattles around. No wonder it was hard to get a good seal. That piece of metal strapping was inside the muffler, I guess it was supposed to be some type of gasket? The muffler gets slightly narrower a little ways in and the header wants to stop there. Is that normal or should I force it? The single mounting bolt is stuck. At this point I'm not sure it matters. -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by Gort on 05/19/09 at 18:31:44 Mine goes on to the point of allowing 5/16" between the mouth of the muffler and the shoulder on the Savage pipe. I had to use steel shim stock around the Savage pipe. I then firmly supported and blocked the Savage pipe, and then placed a piece of 2X4 against the output of the Dyna muffler and tapped it repeatedly with a hammer. I used no sealant, and with a Harley clamp, there are no leaks. The Savage heat shield bolts into place over the joint. |
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Title: Re: Exhaust doesn't line up Post by John_D on 05/19/09 at 20:11:04 5B52575E445357360 wrote:
Don't know anything about the reducer, but thought I'd mention that quite a few people on here have had negative experiences with this particular ebay seller "flightsimshop". My public service announcement of the day! :D |
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Title: Re: Exhaust doesn't line up Post by marshall13 on 05/19/09 at 20:52:00 757C79706A7D79180 wrote:
check your headpipe, there's 1 on it in the pic... that's the adaptor the muff isnt sitting on properly.... sorry if i was ambiguous...lol |
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Title: Re: Exhaust doesn't line up Post by Yonuh Adisi on 05/19/09 at 20:55:49 636A6F667C6B6F0E0 wrote:
Do NOT buy from that seller. Bad news and don't buy from Kwikbay either. |
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Title: Re: Exhaust doesn't line up Post by marshall13 on 05/19/09 at 20:57:47 6166792A0 wrote:
as i pointed out in another thread(too late for Diamond Jim though), these sealers are to be used very sparingly... just wetting the inner surface of the female side for 1/2 an inch is plenty... otherwise, it becomes a most tenacious high temp adhesive... no gobs at all... |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/20/09 at 06:54:11 797566677C7578782527140 wrote:
Um... I assume you mean part #5 in the fiche. http://fiche.ronayers.com/Index.cfm/Module/Main/TypeID/26/Type/Motorcycle/MakeID/2/Make/Suzuki/YearID/48/Year/2007/ModelID/7562/Model/LS650/GroupID/358581/Group/MUFFLER_ I don't think that's on the header. I took a picture of the end of the header, but didn't upload it. It looks like the header is three layers. Edit: Options? 1) Put it back the way it was, hope it stays. 2) Add a shim and/or sealant 3) Add an adapter with a (7 degree ??) bend - what diameter? 4) Force the muffler on further 5) other? 6) all of the above I'm a little concerned about the tension on the joint. I guess that means I should find a place to make an adapter. -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by diamond jim on 05/20/09 at 09:22:45 Yep, I used this: http://www.itwconsumer.com/productfiles/product_62.jpg Think of it as Amish pipe welder. |
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Title: Re: Exhaust doesn't line up Post by marshall13 on 05/20/09 at 09:41:58 options: re-assemble as it was(ill bet you dont like that 1)... fab adaptor for muffler rail to muffler hanger, to move muff mount hole forward an inch or 2(piece of flat stock with 3 holes, 2 to line up with slot on muff, 1 to line up with mounting bracket).... bend OEM muff mount bracket for same effect as option 2.... fab 1 3/4 id to 1 3/4 od adaptor to fill missing length(add 7 degree bend if you like)... leave muff off, re-jet, and learn to enjoy hot gas massaging your ankle at stops.... ill take your word the tubing adaptor sleeve isnt on the headpipe, though in your pics it sure looks like 1 is there, that sharp corner forward of the muff inlet sure looks like the forward shoulder of 1.... measure the end of your headpipe where the muff currently fits.. if it's 1 5/8 od, no adaptor is present, and a piece of straight 1 3/4 tube can make your lengthening sleeve... if it measures 1 3/4 od, then you'll need a 1 3/4 female to male tube.... |
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Title: Re: Exhaust doesn't line up Post by marshall13 on 05/20/09 at 09:46:11 707D75797B7A707E7D79140 wrote:
if you end up using the "smoke wrench separation technique" listen for a "tink" that sounds different than the ones from pipe expansion... that'll be the bond failing.... that's when you wrestle the headpipe free |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/20/09 at 16:37:56 0E0211100B020F0F5250630 wrote:
The OD of the header is roughly 1 5/8" (1.67" according to an electronic caliber - but suspect the skill of the measurer). The ID of the OEM muffler is roughly the same. The ID of the HD muffler is roughly 1 3/4" (1.73"). I've added a picture of the end of the header. http://picasaweb.google.com/mdahrea/Muffler?authkey=Gv1sRgCOrI5KKr5ubRIQ&feat=directlink Without force, there's about 7/16" from the mouth of the muffler to the shoulder on the header. Sounds like I need a 1/16" shim or an extender with a 1 5/8" ID on one end and a 1 3/4" OD on the other. What can I use for a shim? Would a beer can melt? Reading the thread by haulback, it sounds like he's been successful getting a muffler shop to make an adapter. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1242565781 I may have to go that route. Other than a new header gasket, what else will I need to buy if I have to take it apart? This is going to sound like a stupid question: Shouldn't I ride the Savage to the muffler shop so they can make sure it fits? It's been beautiful the last couple days and I'm becoming annoyed I'm not riding. >:( -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by marshall13 on 05/20/09 at 17:13:47 6B62676E746367060 wrote:
The OD of the header is roughly 1 5/8" (1.67" according to an electronic caliber - but suspect the skill of the measurer). The ID of the OEM muffler is roughly the same. The ID of the HD muffler is roughly 1 3/4" (1.73"). I've added a picture of the end of the header. http://picasaweb.google.com/mdahrea/Muffler?authkey=Gv1sRgCOrI5KKr5ubRIQ&feat=directlink Without force, there's about 7/16" from the mouth of the muffler to the shoulder on the header. Sounds like I need a 1/16" shim or an extender with a 1 5/8" ID on one end and a 1 3/4" OD on the other. What can I use for a shim? Would a beer can melt? Reading the thread by haulback, it sounds like he's been successful getting a muffler shop to make an adapter. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1242565781 I may have to go that route. Other than a new header gasket, what else will I need to buy if I have to take it apart? This is going to sound like a stupid question: Shouldn't I ride the Savage to the muffler shop so they can make sure it fits? It's been beautiful the last couple days and I'm becoming annoyed I'm not riding. >:( -D. Dwarf [/quote] ok, od is 1 5/8... thats the rough id of 1 3/4 od exhaust tubing... so, hit your local purveyor of auto part, and get as short a length of 1 3/4 as they sell... you only need a few inches... use 2 clamps(1 for each joint, headpipe to your new piece, new piece to muff) make it long enough you can get both on and sealed (dont crowd the clamps)... use the factory end on the headpipe, and if your cut is a little offsquare on the other end, its hidden inside the muff inlet... after you get it all lined up and together loose, loosen up the headpipe retaining bolts at the head, and then tighten everything in sequence, starting at the head, and ending at the muff support.... if you're gonna do the 7 degree bend, then just get the whole shebang at a muffler shop... edit... i just looked at your new pic, and re=read your dimensions... the 7/16 long section of 1 5/8(the smallest diameter piece of pipe, left in pic) is the headpipe.... you then have a cylindrical sleeve(a couple inches long, heading right in the pic), that ends in a shoulder, then the curve of the outer pipe of the header... the id of the adaptor piece you are fabbing has to fit the od of that larger section behind the 7/16 long stub.... it has to butt against the shoulder at the right end of it in the pic.... the 7/16 long stub isnt long enough to clamp to, it will always leak if you clamp there... so, pull out your calipers again, and measure that cylindrical section just to the right of the stub in the pic.. that will be the id of the front of your adaptor... the other end of your adaptor will be 1 3/4 od... now for the explanation of the solution and problem... the muff mount bracket, and the rail for the bolt on the muff kept the muffler from actually sealing on that cylindrical section, as the mount kept the muff too far to the rear...the muff inlet should have butted against that shoulder, it didnt in your pics....the short sleeve you are fabbing fits over the full length of the headpipe, from that shoulder to the tip, plus a couple inches to go in the muff inlet... that allows the adaptor you fabbed to seal on the headpipe, then the muff to seal onto the adaptor, and the rail slot to align with the mount for the muff... your finished piece should be somewhere around 5-7 inches long(length of headpipe tip to shoulder, plus depth of inlet nipple in muff, subtract a half inch for fitting, equals the length of your adaptor piece...) im hoping this verbose explanation clarifies what im talking about, as opposed to just further confusion....lol |
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Title: Re: Exhaust doesn't line up Post by Staplebox on 05/20/09 at 18:30:02 What can I use for a shim? Would a beer can melt? Thats what I used. Busch I believe. Double thickness, about an inch or so wide and just long enough to wrap around and overlap a smidge. I initially used it with a Dyna and it also worked with the Hard Krome I have now. It didn't melt with the Dyna. |
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Title: Re: Exhaust doesn't line up Post by ero4444 on 05/20/09 at 18:49:57 beer can sounds ideal - aluminum melts at 660C, engine gets no hotter than 400F (about 200C). Can coating will smoke off fast. not Busch! PAABBBSSTTTT BLUUUUUEE RIBBONNNNN! (Dennis Hopper quote from Blue Velvet. no motorcycles) |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/20/09 at 18:57:36 484457564D4449491416250 wrote:
The OD of the sleeve is 1 5/8. I assumed that was part of the header. The Harley muffler won't butt up against the shoulder. The shoulder is roughly 2 1/2" from the end. About 2" into the muffler, it narrows. I'm not sure how much. Which is why in the pictures there's roughly 1/2" between the muffler inlet and the sleeve shoulder. I could try to force it on, but the way it lines up it would be against the rear brake cable. I assume that would be bad. The mounting rail on the muffler is a long slot, so I can adjust it. The bolt that used to be in there was jammed. I messed it up pretty bad getting it out. Time to buy a new bolt! The point being that the mounting didn't affect how far it fit over the header. Just the angle. I think it works out to 2 issues. First, the 7 degree angle between the muffler and the header. Second, the ID/OD difference. marshall13 - I appreciate you taking the time to work through this with me. I'm not intentionally being slow, I'm just new to this. Does anyone know where the 7 degrees came from? I assume someone measured the stock muffler. -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/20/09 at 18:59:09 76617C27272727130 wrote:
Actually, I think all I have are bottles. That probably wouldn't work as well. -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by grandpa on 05/20/09 at 22:12:24 I tried the adapter pipes from the 'zone, 2 HD clamps and still had leaks. Finally bit the bullet and took the whole thing to a muffler shop. Ten minutes and $20.00 later it's solidly welded and no leaks.Make sure you put the header clamp on before you weld it up :'(. Will cost you $20.00 more if you don't :'( :'( :'( :'( :'(don't ask me how I know!! |
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Title: Re: Exhaust doesn't line up Post by Educatedredneck on 05/20/09 at 23:27:16 DD, Take your muffler canister and your header pipe to a muffler shop. They'll fix you right up with a custom adapter pipe, and with two harley 1 3/4" muffler clamps, you will be golden. And once this is done, you should not have any more leaks. Trying to find a premade adapter pipe is a waste of time, don't ask how I know. Using a beer can as a gasket is a stop gap solution at best. Custom adapter pipe is the way to go. You do not need the 7 degree bend in the pipe. Just clean your brake arm off once in a while. |
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Title: Re: Exhaust doesn't line up Post by marshall13 on 05/21/09 at 01:40:28 7A73767F657276170 wrote:
The OD of the sleeve is 1 5/8. I assumed that was part of the header. The Harley muffler won't butt up against the shoulder. The shoulder is roughly 2 1/2" from the end. About 2" into the muffler, it narrows. I'm not sure how much. Which is why in the pictures there's roughly 1/2" between the muffler inlet and the sleeve shoulder. I could try to force it on, but the way it lines up it would be against the rear brake cable. I assume that would be bad. The mounting rail on the muffler is a long slot, so I can adjust it. The bolt that used to be in there was jammed. I messed it up pretty bad getting it out. Time to buy a new bolt! The point being that the mounting didn't affect how far it fit over the header. Just the angle. I think it works out to 2 issues. First, the 7 degree angle between the muffler and the header. Second, the ID/OD difference. marshall13 - I appreciate you taking the time to work through this with me. I'm not intentionally being slow, I'm just new to this. Does anyone know where the 7 degrees came from? I assume someone measured the stock muffler. -D. Dwarf [/quote] i think the 7 degrees came from trig...lol not a problem, i enjoy helping... ok, finally im seeing the whole pic.... the twist i saw at the muff inlet was because if straight it fouled the brake cable... ok, so your sleeve can safely be made from straight 1 3/4 pipe (1 3/4 od, 1 5/8ish id)... may as well just hit the muff shop, as you need the bend... measure how long form the shoulder on headpipe to end.. add an inch, thats where the bend goes... add the depth of the inlet of the muff.. that's your overall length(minimum, though you can make it as long as you like)... get the shop to expand the headpipe end of the new piece just a little... dont forget 2 clamps... with your new hanger bolt, get a few washers, that way if the rail is offset from the mount, you can fill in between.... you might want to take the muff to the shop with you, and get the inlet expanded a little too... the more lap in the joints, the better the seal.... |
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Title: Re: Exhaust doesn't line up Post by Mortation on 05/21/09 at 06:05:07 I was just thinking about revisiting this as I still have some backfiring issues. When I first got my bike I had the same problem, I had a longer reducer though. Here is what I did: 1) Took the whole exhaust off. used WD40 and a rubber mallet to drive the reducer tight into the harley muffler and clamped it on. No play, no gaps. 2) I wrapped muffler tape around the bottom of the header where the reducer slides on. You wont get a tight fit because the reducer is standard and the header is metric. The muffler tape creates a wide seal for two reasons. 1) it allows a snug fit on the reducer to prevent air leaks. 2) its wide enough to allow the reducer to be slightly angled away from the chrome part of the header. The slight angle is needed to allow you to bolt down the muffler, other wise its to turned in and rubs on the brake cable. The end result is pretty good. I think I still have a small leak so I was thinking about pulling it off and making a slice one the reducer so when I clamp it down the metal compresses tight to the muffler tape. Or after reading this hell I may take it to a local muffler shop lol. |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/21/09 at 12:59:58 I've found posts that recommend 7-10 inches in length and 7-10 degrees in bend. I wonder why there's such variation? Or did someone just get their numbers backwards. I called around. The motorcycle shops weren't very helpful ("we'll have to see it and do the work ourselves"). A few of the muffler shops refused to touch it ("No"). Found one place (national chain) that would "see what they could do, just throw our guy a few bucks". Hopefully, I'll be able to get it taken care of tomorrow. With the bend in it, am I limited to the stock heat shield? Will the stock shield stay on with just the single clamp? Other suggestions? The muffler guy said the pipe would be "aluminized". Is that good? -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by haulback on 05/21/09 at 19:42:41 DD...... Just get the oldest guy in the shop to do the work, and park the bike beside him so he won't have to walk too far......Should be no real drama involved in the operation to speak of - it's all pretty basic stuff for a muffler shop (ever had a look at some of the bendy tailpies on cars? - they have to fab up those sometimes too) The 7 degree bend is there so that your new muffler will NOT point at the brake arm ... hence, no wiping soot and carbon off it for the rest of your life. on my install the muffler (a dyna) sits far enough back that i can only get one mounting bolt in it using the stock SUZ braket, but is certainly seems solid enough. The Dyna is waaaay lighter than the stock pipe, Good luck on getting it hung on the bike.... |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/22/09 at 07:37:54 haulback - Which model exhaust do you have? Mine is 64941-01 from a HARFXD1450. I'm a little concerned about the amount of space for a bend. With one mounting bolt and the muffler all the way back, there's about 1/2" between the muffler and the header. Hopefully that will be enough room. I should have bought a flat piece of aluminum to extend the muffler bracket with. Mow the lawn, then off to the muffler shop! -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by AngloSaxon on 05/22/09 at 11:12:39 Why don't you just ride it with only the header? How simple is that??? LMAO..... |
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Title: Re: Exhaust doesn't line up Post by High-Def on 05/22/09 at 11:30:05 3720212B20262E7277747577450 wrote:
Don't know anything about the reducer, but thought I'd mention that quite a few people on here have had negative experiences with this particular ebay seller "flightsimshop". My public service announcement of the day! :D[/quote] Sorry to be off topic but, thanks for the tip I just removed 5 items from myebay I was watching from this seller. I had to check when Yonuh Adisi spoke up as well. Ok now back to the OP. |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/22/09 at 14:47:52 5D727B70734F7D6473721C0 wrote:
The guy at the shop offered just put a straight 1 3/4" pipe on it. ;D The guy was very helpful, apparently he used to bend pipe for a motorcycle shop. Rides a Harley, but I didn't hold it against him. He was impressed with the little S40. I didn't have the second clamp when I was at the muffler shop. (stupid stupid stupid) I rode home with it barely on. So I didn't know if it was successful or not when I left the shop. http://picasaweb.google.com/mdahrea/Muffler?authkey=Gv1sRgCOrI5KKr5ubRIQ&feat=directlink Added some pictures of what it currently looks like. It still leaks. Not much when idling, I couldn't feel it. But it didn't pass the bubble test. Not sure what else to do. :-/ -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/22/09 at 17:13:08 I didn't tighten the clamps with a torque wrench (stupid stupid stupid). Just now I grabbed my click-style torque, set it to 50, and *click*. At least 50. Hope that's not too much. Couple possibilities: a) Clamps can't get small enough. These HD clamps won't go less than about 1 3/4". b) Adapter piece isn't ideal. Not much I can do about that. Maybe I'll stop by and see if the guy is working tomorrow. c) other? -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by haulback on 05/22/09 at 21:37:44 did you load up flared end (where it slips over header) with high-temp silicone before installing?? Mine was a 'light' drive fit, we siliconed it well, and I have NO clamp on that end at all. ...no leaks. |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/23/09 at 09:31:55 Just bought Permatex Ultra Copper. Going to try that. Had to take a pipe wrench to the adapter to get it out of the muffler. Man it was stuck in there. No idea how it was leaking. It's a little manged now, hope I didn't damage a surface I need. -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/23/09 at 11:23:02 I chickened out and went to a different shop and got Muffler & Tailpipe Sealer. It's all together now, the real question is should I torque down the clamps now or later. -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/23/09 at 12:28:55 Waited 30 minute. Torqued the clamps to 50 lbs. Won't be able to ride for a few days. That will let it set up real nice. After that, I don't care if it leaks. >:( -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by Yonuh Adisi on 05/23/09 at 12:56:42 I have an exhaust leak as well, but too financially unstable at the moment to fix it. (Muffler is welded to pipe by PO.) |
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Title: Re: Exhaust doesn't line up Post by diamond jim on 05/23/09 at 18:58:17 0F06030A100703620 wrote:
The guy at the shop offered just put a straight 1 3/4" pipe on it. ;D ... [/quote] So you didn't just go with the simple 1 3/4" pipe? |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/24/09 at 01:37:36 6B666E6260616B6566620F0 wrote:
The guy at the shop offered just put a straight 1 3/4" pipe on it. ;D ...[/quote] So you didn't just go with the simple 1 3/4" pipe?[/quote] I don't have any baffles and I don't want it to be obnoxiously loud. I don't drink the "loud pipes saves lives" kool-aid. So he put a bend (not sure the angel) in a 1 3/4" pipe and got it to fit. You can barely tell there's a bend in the 5" of pipe. I can see myself wanting to bob my S40. Then I'll consider a straight pipe. I'm too new to the hobby to consider something that drastic. -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by diamond jim on 05/24/09 at 09:34:30 Using a baffle is pretty much a given and makes it quieter that a sporty muffler with the metal plate popped out. Tuning the baffle is fun IMO. |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/24/09 at 12:03:24 3D30383436373D333034590 wrote:
Someday. I'm still an amateur. :) Since I have your attention, care to share where you got your 'sampson 10" long for 2" pipe heat shield' from? My ebay-foo is weak. -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by diamond jim on 05/25/09 at 06:19:58 232A2F263C2B2F4E0 wrote:
Someday. I'm still an amateur. :) Since I have your attention, care to share where you got your 'sampson 10" long for 2" pipe heat shield' from? My ebay-foo is weak. -D. Dwarf [/quote] I went with it because it was one of a few that was actually 10" long, would fit and was reasonably priced. There are plenty of 7" ones for the same price. There are some that are like 24" but they were way too much for my budget. I wanted 2" diameter cause I wanted to be able to wrap a layer of heat wrap under each heat shield clamp. This was to prevent any possible rattle (I can see now that rattling woudln't be a problem) and because I was mounting it on bare pipe I didn't want it to get too hot and turn colors. It seems like I got mine off of ebay. It was in a box labeled Sampson and no other markings. It seemed like it was a box that might have been inside a box for a complete exhaust system but the owner didn't use it and so sold it. But here are some links: http://www.cbxmanmotorcycles.com/productinfo.aspx?productid=DS-203074&affid=4 http://underbid.com/action/display/item/780-1063049945/sku/2666.html |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/25/09 at 16:01:05 Thanks D. Jim. http://picasaweb.google.com/mdahrea/Muffler?authkey=Gv1sRgCOrI5KKr5ubRIQ&feat=directlink Added some pictures of it all together. The heat shield is tipped as far toward the inside as I can (it hits the clamps) to reduce the heat on the brake lines. Of course, it's clamped directly to the single walled pipe, so it'll probably act more like a heat sink than a shield. I'm wondering what I should do about the heat issue? The options I've come up with so far: * Cut notches in this small heat shield so it'll fit between the clamp bolts and buy a 7" for the outside. * Exhaust wrap both joints and clamps (with or without the shields). I'm open to suggestions. -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by Rustbucket on 05/25/09 at 16:09:06 I Installed my dyna muffler yesterday following some of the good advice i found on this site. Something that helped decrease the angle slightly was removing the asbestos pad on the heat shield at the footpeg. This lets you turn the header pipe a taste outward. I installed the dyna using a HD clamp. (bad ass clamp btw!) tight fit no slop but it leaked a little. Enter this from Auto Zone> http://www.itwconsumer.com/productfiles/product_62.jpg Goobered alot all around the pipe, reinstalled the dyna and clamped her down TIGHT. Pay attention that you have the dyna rear bracket lined up with the rear support bracket. A good man can get a bolt and nut in that rear mount and bolt her down.. I however, Am not that man lol.. I said screw it after 30 minutes but i see how it could be done with a smaller nut than i tried. Instead, A decent hose clamp from bracket to dyna support holds it good n tight. You can reuse the S-40's big heatshield to hide your clamp and hide the exhaust goo goopy part. Looks ok enough for now. Rode her today!! Just 20 -30 min or so in city.. No leaks and i like the dyna sound alot! Not as loud as i thought it'd be but it sounds really good!!! I love it! Will put up a pic shortly of the results. Thanks to all who offered advice. http://i40.tinypic.com/2vxftiv.jpg http://i41.tinypic.com/19r3lz.jpg http://i41.tinypic.com/35id2jb.jpg http://i42.tinypic.com/25kln2c.jpg http://i39.tinypic.com/30j39c9.jpg http://i41.tinypic.com/c7xjo.jpg |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/25/09 at 16:53:07 Stock heat shield is an option. I really don't like the way it looks, so it's a last resort. Thanks for the pics, glad it worked out for you. -D. Dwarf edit: attempt at image... http://lh3.ggpht.com/_gpMEVRBlMes/ShsgOZg-oII/AAAAAAAAAgw/zp4qPiFac7s/s144/Muffler%20003.jpg (http://picasaweb.google.com/lh/photo/yG6c3v__3lbLiRU4sJoUZw?authkey=Gv1sRgCOrI5KKr5ubRIQ&feat=embedwebsite) It's an image! It's a link! Wonder why it's so small. Must be Picasa. |
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Title: Re: Exhaust doesn't line up Post by diamond jim on 05/25/09 at 17:01:09 Rustbucket, I see you used Amish pipe welder just like I did. It works so good my pipe has become one solid piece. I've removed/reinstalled it three times now as a complete unit. To get it apart I'll need to do what Marshall said and apply flame to heat the joint. |
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Title: Re: Exhaust doesn't line up Post by Rustbucket on 05/25/09 at 19:27:25 4940454C564145240 wrote:
The stock shield isn't my first choice either, I'll look into an alternative when i have the extra $$$ 222F272B2928222C2F2B460 wrote:
Until this topic i didn't know there was a decent exhaust sealer out there. haha Amish pipe welder is what i meant to say. Hope i never need to remove it because I gobbed extra stuff around the joint. Took her out again tonight, Did I mention how much i love the new sound!! Now I might need to look into rejetting, It has a blaaa sluggish feeling at about 70 mph |
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Title: Re: Exhaust doesn't line up Post by marshall13 on 05/25/09 at 19:31:45 624543445245535B5544300 wrote:
The stock shield isn't my first choice either, I'll look into an alternative when i have the extra $$$ 222F272B2928222C2F2B460 wrote:
Until this topic i didn't know there was a decent exhaust sealer out there. haha Amish pipe welder is what i meant to say. Hope i never need to remove it because I gobbed extra stuff around the joint. Took her out again tonight, Did I mention how much i love the new sound!! Now I might need to look into rejetting, It has a blaaa sluggish feeling at about 70 mph [/quote] if you ever need to disassemble it, remember the "smokewrench" is the exhaustmans best friend....lol "gooey gobs" leads me to believe you might want a "needle scaler" too...lol |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/26/09 at 13:11:10 No leaks. That 4" heat shield isn't going to work out. It rattles at certain RPM. Edit: How would I go about cutting that heat shield? -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/27/09 at 07:00:50 Bump in case my edit was missed: How would I go about cutting that heat shield? -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by diamond jim on 05/27/09 at 07:03:32 1st choice: Plasma cutter. 2nd choice: Angle grinder then clean up. |
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Title: Re: Exhaust doesn't line up Post by Duane on 05/27/09 at 07:23:39 Is there a alternative heat shield that can be used? That factory looks horrible. |
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Title: Re: Exhaust doesn't line up Post by savagedml on 05/27/09 at 08:09:25 I bought a chrome-plated 1 3/4" x 6" sink tail piece from the plumbing section of the hardware store and sliced it down the middle with my angle grinder, pried it open, and clamped it over the uglies. I have a pic, but work IT security software won't allow me to post pics. I'll try to pm you a shot later tonight. |
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Title: Re: Exhaust doesn't line up Post by Duane on 05/27/09 at 08:15:27 If you can post it in the thread, I'd like to see what it looks like as well. Does it get hot? I already have a colection of pants with holes in the right leg. |
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Title: Re: Exhaust doesn't line up Post by diamond jim on 05/27/09 at 09:07:12 Here's a 7" chrome heat shield for $14.99. http://www.retrocycle.com/CustomChromeParts/2736/Chrome_Exhaust_Heat_Shield.html I've got the 10" one. |
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Title: Re: Exhaust doesn't line up Post by marshall13 on 05/27/09 at 10:23:00 5263777873160 wrote:
just about any thin wall tubing or moderately thin sheet metal can be used... stainless or chrome for a non-painted shield, or practically any metal besides zinc or bizmuth if you plan on painting it(not that one finds much zinc or bizmuth pipe or sheet in the hardware store)... the only limitation is how much elbow grease you're willing to expend to make one...hint for those who would like to make one from thin sheet.. you can "profile" sheetmetal with hoseclamps and a piece of pvc pipe, without getting hammer marks....thicker sheet would require a more robust forming rig.... muffler wrap can be rivetted or screwed to the inner face for insulation(no toasted ankle).... your imagination and fab skills are pretty much the 2 limitations.... |
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Title: Re: Exhaust doesn't line up Post by DrunkenDwarf on 05/27/09 at 10:26:51 How important is it to put something between the single walled exhaust pipe and the bike? -D. Dwarf |
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Title: Re: Exhaust doesn't line up Post by marshall13 on 05/27/09 at 10:30:31 3C353039233430510 wrote:
not very... it might be an issue if you spend lots of time in bumper to bumper 5 feet per minute brooklyn at rush hour traffic, otherwise not so important... |
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Title: Re: Exhaust doesn't line up Post by tomtaz1975 on 05/27/09 at 15:41:41 Since I just wrestled with installing a new muffler and ran across this exact issue, I'll toss in my experience. I bought a long megaphone muffler because I wanted somewhat of an old-style look. That is before I realized the stock muffler angles 5-10 degrees from the header pipe. The new muffler, if straight, would have ended up through the swing-arm and next to the brake control. What I did was add a small section of automotive flexible muffler pipe between the header pipe (You can buy this at any auto store in multiple I.D.'s for about $8/ 2 feet) and the "slip-on". This allowed me to angle the muffler any which way I wanted so I could mate it to the rear. Then I sealed it to the header pipe with a small wrapping of muffler repair tape, which you have to run about 30 minutes to cure it rock hard. I didn't seal it to the slip-on because it is enough of a press-fit that it isn't leaking and still allows me to remove it in two pieces. This is an "ugly" fix, but I was going to add performance exhaust wrap anyways...which I did, and that covers it all up so no one can tell what I did underneath. |
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Title: Re: Exhaust doesn't line up Post by savagedml on 05/27/09 at 20:10:20 Here's the link to a pick (not the best) of my sink tailpiece muffler-uglies hider http://www.bikepics.com/pictures/1665822/ |
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