SuzukiSavage.com - Why won't my MAC exhaust fit??

toddlamp8

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Why won't my MAC exhaust fit??
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:

What is going on?

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barry68v10 Serious Thumper Offline Posts: 955 Maryland Gender:	Re: Why won't my MAC exhaust fit?? Reply #1 - 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"...
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ls650v Junior Member Offline 97 savage Posts: 73 Clinton Twp, MI Gender:	Re: Why won't my MAC exhaust fit?? Reply #2 - 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.
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toddlamp8 Full Member Offline I love YaBB 1G - SP1! Posts: 241 Gender:	Re: Why won't my MAC exhaust fit?? Reply #3 - 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.
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Why won't my MAC exhaust fit?? Reply #4 - 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...???
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toddlamp8

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Re: Why won't my MAC exhaust fit??
Reply #5 - 11/10/07 at 10:09:44

Savage_Greg wrote on 12/31/69 at 16:00:11:

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.

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bill67 Serious Thumper Offline old tired Posts: 8517 genoa city wisconsin Gender:	Re: Why won't my MAC exhaust fit?? Reply #6 - 11/10/07 at 10:26:11 Was that muffler for the savage? If it was i would call them and tell them.
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vtail Senior Member Offline life's short, ride fast Posts: 408 Portland,OR Gender:	Re: Why won't my MAC exhaust fit?? Reply #7 - 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.
Back to top	'07, White spacer REMOVED, 152,5 main jet, K&N drop-in filter, Mac exh, Sigma 906, ENM PT15B2 tach, factory s bags, shield, backrest/lug rack, crashbar, Kuryakyn 7980 ext hwy pegs,412-4233C+'09 C50T IP Logged

toddlamp8 Full Member Offline I love YaBB 1G - SP1! Posts: 241 Gender:	Re: Why won't my MAC exhaust fit?? Reply #8 - 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.
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vtail

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Re: Why won't my MAC exhaust fit??
Reply #9 - 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. Wink

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'07, White spacer REMOVED, 152,5 main jet, K&N drop-in filter, Mac exh, Sigma 906, ENM PT15B2 tach, factory s bags, shield, backrest/lug rack, crashbar, Kuryakyn 7980 ext hwy pegs,412-4233C+'09 C50T

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toddlamp8 Full Member Offline I love YaBB 1G - SP1! Posts: 241 Gender:	Re: Why won't my MAC exhaust fit?? Reply #10 - 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.
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toddlamp8 Full Member Offline I love YaBB 1G - SP1! Posts: 241 Gender:	Re: Why won't my MAC exhaust fit?? Reply #11 - 11/10/07 at 11:29:43 I think tonight I will put a bunch of slits in it and try again.
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Paladin.

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Re: Why won't my MAC exhaust fit??
Reply #12 - 11/10/07 at 11:34:01

vtail wrote on 12/31/69 at 16:00:11:

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. Wink

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

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vtail

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Re: Why won't my MAC exhaust fit??
Reply #13 - 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

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'07, White spacer REMOVED, 152,5 main jet, K&N drop-in filter, Mac exh, Sigma 906, ENM PT15B2 tach, factory s bags, shield, backrest/lug rack, crashbar, Kuryakyn 7980 ext hwy pegs,412-4233C+'09 C50T

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vtail Senior Member Offline life's short, ride fast Posts: 408 Portland,OR Gender:	Re: Why won't my MAC exhaust fit?? Reply #14 - 11/10/07 at 11:44:32 Paladin, consider it done
Back to top	'07, White spacer REMOVED, 152,5 main jet, K&N drop-in filter, Mac exh, Sigma 906, ENM PT15B2 tach, factory s bags, shield, backrest/lug rack, crashbar, Kuryakyn 7980 ext hwy pegs,412-4233C+'09 C50T IP Logged