SuzukiSavage.com - Exhaust doesn't line up

Rustbucket

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Re: Exhaust doesn't line up
Reply #45 - 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>

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.

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DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: Exhaust doesn't line up Reply #46 - 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... It's an image! It's a link! Wonder why it's so small. Must be Picasa.
Back to top	« Last Edit: 05/25/09 at 19:31:48 by DrunkenDwarf » Pearl White 2007 S40; Dyna exhaust; Current jets: 52.5 w/ bleed (2 turns out) / 1.5mm (0.06") spacer / 150; raptor petcock IP Logged

diamond jim Serious Thumper Offline Posts: 1425 North Alabama Gender:	Re: Exhaust doesn't line up Reply #47 - 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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Rustbucket

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Re: Exhaust doesn't line up
Reply #48 - 05/25/09 at 19:27:25

DrunkenDwarf wrote 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

The stock shield isn't my first choice either, I'll look into an alternative when i have the extra $$$

diamond jim wrote 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.

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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marshall13

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Re: Exhaust doesn't line up
Reply #49 - 05/25/09 at 19:31:45

Rustbucket wrote on 05/25/09 at 19:27:25:

DrunkenDwarf wrote 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

The stock shield isn't my first choice either, I'll look into an alternative when i have the extra $$$

diamond jim wrote 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.

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

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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DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: Exhaust doesn't line up Reply #50 - 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
Back to top	« Last Edit: 05/26/09 at 17:44:45 by DrunkenDwarf » Pearl White 2007 S40; Dyna exhaust; Current jets: 52.5 w/ bleed (2 turns out) / 1.5mm (0.06") spacer / 150; raptor petcock IP Logged

DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: Exhaust doesn't line up Reply #51 - 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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diamond jim Serious Thumper Offline Posts: 1425 North Alabama Gender:	Re: Exhaust doesn't line up Reply #52 - 05/27/09 at 07:03:32 1st choice: Plasma cutter. 2nd choice: Angle grinder then clean up.
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Duane Senior Member Offline Creatively Maladjusted Posts: 335 Terra Plane Gender:	Re: Exhaust doesn't line up Reply #53 - 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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savagedml Full Member Offline Paid Alliance Membership (07/09) Posts: 246 Portsmouth, VA Gender:	Re: Exhaust doesn't line up Reply #54 - 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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Duane Senior Member Offline Creatively Maladjusted Posts: 335 Terra Plane Gender:	Re: Exhaust doesn't line up Reply #55 - 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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diamond jim Serious Thumper Offline Posts: 1425 North Alabama Gender:	Re: Exhaust doesn't line up Reply #56 - 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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marshall13

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the first step is to
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Re: Exhaust doesn't line up
Reply #57 - 05/27/09 at 10:23:00

Duane wrote on 05/27/09 at 07:23:39:

Is there a alternative heat shield that can be used? That factory looks horrible.

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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DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: Exhaust doesn't line up Reply #58 - 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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marshall13 Senior Member Offline the first step is to admit your ignorance Posts: 301 Fort Lauderdale FL Gender:	Re: Exhaust doesn't line up Reply #59 - 05/27/09 at 10:30:31 DrunkenDwarf wrote 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 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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