SuzukiSavage.com - Exhaust doesn't line up

AngloSaxon Full Member Offline I'd rather have one big one than four small ones. Posts: 141 Framingham MA Gender:	Re: Exhaust doesn't line up Reply #30 - 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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Seth C.

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Re: Exhaust doesn't line up
Reply #31 - 05/22/09 at 11:30:05

John_D FSO wrote on 05/19/09 at 20:11:04:

DrunkenDwarf wrote 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...

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

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! Cheesy

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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2001 Suzuki Savage LS650

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DrunkenDwarf

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Re: Exhaust doesn't line up
Reply #32 - 05/22/09 at 14:47:52

AngloSaxon wrote on 05/22/09 at 11:12:39:

Why don't you just ride it with only the header? How simple is that??? LMAO.....

The guy at the shop offered just put a straight 1 3/4" pipe on it. Grin

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...
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. Undecided

-D. Dwarf

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Pearl White 2007 S40; Dyna exhaust; Current jets: 52.5 w/ bleed (2 turns out) / 1.5mm (0.06") spacer / 150; raptor petcock

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DrunkenDwarf

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Re: Exhaust doesn't line up
Reply #33 - 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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Pearl White 2007 S40; Dyna exhaust; Current jets: 52.5 w/ bleed (2 turns out) / 1.5mm (0.06") spacer / 150; raptor petcock

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haulback YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 25 Vancouver, British Columbia, C Gender:	Re: Exhaust doesn't line up Reply #34 - 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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DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: Exhaust doesn't line up Reply #35 - 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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DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: Exhaust doesn't line up Reply #36 - 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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DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: Exhaust doesn't line up Reply #37 - 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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Yonuh Adisi FSO Serious Thumper Offline Savage Jedi (Knight) Posts: 3622 Pilot Valley NV, aka Tatooine Gender:	Re: Exhaust doesn't line up Reply #38 - 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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diamond jim Serious Thumper Offline Posts: 1425 North Alabama Gender:	Re: Exhaust doesn't line up Reply #39 - 05/23/09 at 18:58:17 DrunkenDwarf wrote on 05/22/09 at 14:47:52: AngloSaxon wrote on 05/22/09 at 11:12:39: Why don't you just ride it with only the header? How simple is that??? LMAO..... The guy at the shop offered just put a straight 1 3/4" pipe on it. ... So you didn't just go with the simple 1 3/4" pipe?
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DrunkenDwarf

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Re: Exhaust doesn't line up
Reply #40 - 05/24/09 at 01:37:36

diamond jim wrote on 05/23/09 at 18:58:17:

DrunkenDwarf wrote on 05/22/09 at 14:47:52:

AngloSaxon wrote on 05/22/09 at 11:12:39:

Why don't you just ride it with only the header? How simple is that??? LMAO.....

The guy at the shop offered just put a straight 1 3/4" pipe on it. Grin

...

So you didn't just go with the simple 1 3/4" pipe?

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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Pearl White 2007 S40; Dyna exhaust; Current jets: 52.5 w/ bleed (2 turns out) / 1.5mm (0.06") spacer / 150; raptor petcock

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diamond jim Serious Thumper Offline Posts: 1425 North Alabama Gender:	Re: Exhaust doesn't line up Reply #41 - 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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DrunkenDwarf

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Re: Exhaust doesn't line up
Reply #42 - 05/24/09 at 12:03:24

diamond jim wrote 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.

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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Pearl White 2007 S40; Dyna exhaust; Current jets: 52.5 w/ bleed (2 turns out) / 1.5mm (0.06") spacer / 150; raptor petcock

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diamond jim

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Re: Exhaust doesn't line up
Reply #43 - 05/25/09 at 06:19:58

DrunkenDwarf wrote on 05/24/09 at 12:03:24:

diamond jim wrote 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.

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

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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DrunkenDwarf

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Re: Exhaust doesn't line up
Reply #44 - 05/25/09 at 16:01:05

Thanks D. Jim.

http://picasaweb.google.com/mdahrea/Muffler?authkey=Gv1sRgCOrI5KKr5ubRIQ&feat...

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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Pearl White 2007 S40; Dyna exhaust; Current jets: 52.5 w/ bleed (2 turns out) / 1.5mm (0.06") spacer / 150; raptor petcock

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