SuzukiSavage.com

orrin7

Ex Member

exhaust
02/07/06 at 16:11:03

one of the guys at work has a 2002 savage . his is the reason i bought my s40. he has a screamin eagle muffler on it from a sportster. when he saw my muffler , he told me his problem. his leaks right where it joins the header on the side . he said he has tried everything he can think of to stop it with no results. he came by my house today and i tried several things with no results . can anyone help him.

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Reelthing Serious Thumper Alliance Member Offline Fish or ride that is the question Posts: 5397 Houston,Tx Gender:	Re: exhaust Reply #1 - 02/07/06 at 16:42:37 whats the inside diameter? - one fellow just had the SAII welded to the head pipe
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Hammy211

Ex Member

Re: exhaust
Reply #2 - 02/07/06 at 17:39:38

Following recommendations from this board, I used pieces of pop can as a shim and a 1 3/4 car muffler bracket I believe. As much shim as I could fit which was two or three layers. No leaks. Problem with his now could be that the metal has already been bent which would make it more difficult to get a good shim in. I have an SE II slash cut muffler off a sportster.

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Jim_R Ex Member	Re: exhaust Reply #3 - 02/07/06 at 19:53:46 tell him to take the muffler off, bring it autozone, and buy a brute force muffler clamp (like 2-3 dollars). That way he can fit the clamp around the muffler and see how close it will fit. Buy the tightest snug one. Using strips of soda cans inbetween works as a gasket under pressure. good luck.
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Max_Morley

Serious Thumper

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LT650 Luxury Touring
& sidecar rig

Posts: 1490
Moses Lake. WA
Gender: male

Re: exhaust
Reply #4 - 02/07/06 at 22:35:20

$10.00 spent at the local performance muffler shop today bought my BiL the adapter that is 7" long has the 10 deg bend in it and is cutom fit the header and muffler. He welded the adapter to the head pipe after we carefull fit the turn on the adapter so the muffler sat parallel to the swing arm and kicked out past the rear brale lever. Left that very snug connection unclamped so there is some give in the syste, as it heats and expands. Use a piece of 1x1 or 1 1/4 x 1 1/4 angle iron on the original bracket and the tab on the HD XL muffler Then used the standard 2" heat shield to cover the adapter. Looks and sounds great. No more heat treating the brake assembly or coke can shims. It looks like it was meant to be. I strongly reccomend this method over shade tree stuff. Max in Moses Lake. Sluggo when are you coming after the SuperTrapp?

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Max at Thumper Acres. '96 Savage bagger, '03 Savage w/Cozy sidecar for wifeni.

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Dynobob Serious Thumper Offline 2003 LS650 (with Supertrapp) Posts: 634 Northern Virginia Gender:	Re: exhaust Reply #5 - 02/07/06 at 23:19:10 Permatex makes a high temp silicone sealer designed for exhausts. Let it cure for 24 hours or you may blow it out. Clean the surfaces with steel wool and some solvent before applying.
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slavy

Serious Thumper

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smart cars for
stupid people

Posts: 710
Phoenix, Arizona
Gender: male

Re: exhaust
Reply #6 - 02/08/06 at 07:36:34

The way You describe the problem- 2 easy solutions:
1. Go in Harbor Fraight and buy an exaust pipe expanding tool. The price will be around $9-10 if it is not on sale and about $5 on sale. Use it where the muffler is deformed and it will work pretty good. The only problem is that HF tools are very low quality and I don't know what is tuffer- the muffler or the tool.
2. Just go in a muffler shop with both pieces and explain the problem. They have professional tools and they deal with these problems all the time. You will get the work done right, You can get some other input about sealing between the 2 parts, and it will not cost You too much.

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The arificial intelligence is no match for the natural stupidity

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Ed L.

Serious Thumper
Alliance Member

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"We All go a
Little Crazy
Sometimes"
Norman Bates

Posts: 2808
Sunny Florida
Gender: male

Re: exhaust
Reply #7 - 02/08/06 at 15:38:17

Get a piece of black thickwalled gas pipe that fits loosely in the exhaust pipe, clamp it in a vice and slip it in the end of the pipe. Then take a hammer (one of my favorite tools) and tap on the exhaust pipe using the gas pipe as an anvil and work out the deformation. Or run down to the local muffler shop and slip the kid in the back a couple bucks to do it up right.

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Silver '02, clubman handle bars, Cobra headlight, Sportster muffler, K+N stock air filter, 152.5 main, Superbrace, oil cooler, 1/2 inch aluminium plate forward controls, spark advance, goes like stink

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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: exhaust Reply #8 - 02/09/06 at 08:20:54 The seal/gasket that Suzuki uses (available at RonAyers.com and others) is pliable and made with metal fibers in it. After trying several things, I noticed this in the parts fiche at RonAyers.com and tried it. It works extremely well.
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