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General Category >> Rubber Side Down! >> Exhaust adapter? Tank cap?
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Message started by SavageMan99 on 08/06/18 at 09:36:51

Title: Exhaust adapter? Tank cap?
Post by SavageMan99 on 08/06/18 at 09:36:51

About got it running.
I need an adapter to connect the exhaust to the harley muffler mounted on the oem brace. It looks about 6 inches with a bend needed.
I need a fuel cap. Tank is locked shut. What fits?

Title: Re: Exhaust adapter? Tank cap?
Post by ohiomoto on 08/06/18 at 09:46:50

I recommend the Ryca adapter for the exhaust. It's a little pricey but works perfect and will save you a lot of time/BS making your own. If you do your own (there are several guides on here) make sure you don't have any air leaks.

Title: Re: Exhaust adapter? Tank cap?
Post by Dave on 08/06/18 at 10:15:01

I don't know that anyone has ever found a fuel cap from any other bike that will work on the Savage.

Here is the specs for an adapter if you want to build your own.....it doesn't have to be stainless - but it is impossible to keep paint on anything that gets that hot.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1353284557

The RYCA is chrome, it fits and holds up pretty well.

Title: Re: Exhaust adapter? Tank cap?
Post by WillytheSavage on 08/06/18 at 12:04:42

Dave, With either of these adapters do you recommend some kind of exhaust paste to seal it up? Or will a clamp do the job just fine?

Title: Re: Exhaust adapter? Tank cap?
Post by SavageMan99 on 08/06/18 at 15:24:33

Thanks on the input.
I found a weld on fuel neck and cap I'll try, maybe. It'll stick up but that goes with the bobber look alright.

Title: Re: Exhaust adapter? Tank cap?
Post by batman on 08/06/18 at 17:13:55

A short length of 1/2 "x1/8" thick flat bar works well for mounting the muffler, drill two holes to pick up the mount on the muffler and one to pickup the last hole in the stock muffler brace. it is easily bent to match the muffler angle it your using an adapt or not.

Title: Re: Exhaust adapter? Tank cap?
Post by Hiko on 08/06/18 at 17:20:03

Two days ago I fitted a Harley Dyna by cutting the inlet of the Dyna 7/8ths way round with a 1mm cut off disc and rewelding using a stick welder and stainless rods to the Suzuki,s 8 degree offset. I also removed the two knobs inside the inlet of the Dyna using a hole saw and drill.
The original Suzuki clamp will fit on the outside with a short piece of 50mm tube under it . It is necessary to split this tube and remove about 5mm to allow it to clamp down properly.
Between the muffler and the header I used a piece of corrugated tin can as a crush sleeve as has been suggested on here. I also used CRC muffler sealant THe Dyna then bolted straight up very easily to the original mounts and right up to the ring on the Header
I also refitted the original heat shield using a hose clamp at the rear
through a small custom made bracket at the rear bolt hole.
Easy modification and works and looks good

Title: Re: Exhaust adapter? Tank cap?
Post by Dave on 08/06/18 at 18:20:37

2436232A3D29263C272A3D7C774F0 wrote:

Dave, With either of these adapters do you recommend some kind of exhaust paste to seal it up? Or will a clamp do the job just fine?

I have never needed any kind of "paste" - but I have been known to use some anti-seize to make getting them apart again a bit easier.

Title: Re: Exhaust adapter? Tank cap?
Post by engineer on 08/06/18 at 19:37:14

SavageMan99, I made an adapter using Dave's drawing but made it slightly shorter to help with the fit up of the brackets on the muffler I bought. I started with a stock exhaust pipe adapter piece I found at a NAPA parts store. I didn't get a perfect fit on one end and there was a small leak. I bought some stuff called muffler cement and stuffed it into the joint and it worked very well.

Title: Re: Exhaust adapter? Tank cap?
Post by justin_o_guy2 on 08/07/18 at 14:55:35

Locksmith to remove cap.
Gut the cap lock
Iggy key to open