Refitting mufflers to exhaust

Hyper Fish

Joined
Jan 7, 2021
Messages
21
Age
46
Location
Adelaide, Australia
It's been some time but I've finally managed to pull the exhaust off my bike. As mentioned previously my bike was stolen and recovered, and the thieves had cut/broken the mufflers off the exhaust pipes. I've bought some second hand mufflers but need to confirm how the attach to the pipes. Pictures show what the ends of the pipes look like, and the muffler end. I can't tell from the diagrams whether the pipes go into the exhaust or the exhaust goes into the pipes. Or is there a joining segment that's missing. Does it look like there are the remains of the prev exhaust still stuck in the ends of the pipes that I need to remove? Any guidance appreciated.
 

Attachments

  • 20210910_165646.jpg
    20210910_165646.jpg
    126.4 KB · Views: 52
  • 20210910_165654.jpg
    20210910_165654.jpg
    72 KB · Views: 49
  • 20210910_165700.jpg
    20210910_165700.jpg
    80.7 KB · Views: 47
  • 20210910_165730.jpg
    20210910_165730.jpg
    156.3 KB · Views: 48
Looks like you have the remains of the ‘soft’ gaskets in the collector there. If you can re-use them I would because they are probably a tenner each or something. More than you think. Plus I doubt you will get them out without ripping them to bits anyway as they are like a wire mesh compacted into a hard resin or similar. I will double check in a mo but I believe the exhaust silencers slip into the collector.


Update. Yep they do. However the standard pipes on mine (2002 registered) look different to yours in image 4. The end of the pipe looks to be the same diameter, not flared? Others will have to step in now, maybe the model years were slightly different? Good luck with it anyway.
 
This is /was a replacement system - you can work out how it goes together with a collar to seal the silencers with the 2 into 1 into 2 collector box.....

1631268985120.png
 
Its been a while, but I would put the new gasket half on the end of the muffler and offer the other half into the collector. I used copper grease on both metal halves to help the metal slip into the gasket. - reason being, if the edge of the pipe catches on the side of the gasket, it wrinkles it, which makes it impossible to fit properly. I had this problem i once so I did it this way and it wirked, so I always did it that way. The original silencer pipe has a rib which helps to push the gasket into place. The clamp squeezes the collector pipe onto the gasket.

Fed up with Honda clamps rusting and breaking, I used stainless steel hose clamps. They worked well, and never broke on me.

The copper grease ? It makes a lot if smoke ans smells horrible when you first fire it up, but it goes away and the parts separate easily afterwards.
 
After you clean out the gasket inside those damaged pipes, you might get a heavy round piece of steel and use it like a mandrel to hammer the bent flanges back into their original shape.
 
Roger. said:
This is /was a replacement system - you can work out how it goes together with a collar to seal the silencers with the 2 into 1 into 2 collector box.....

View attachment 281706
Click to expand...
This system is different to mine. The left pipes into the collector box is all one piece, with the right side disconnecting. Your silencers clearly slip into the flanges on the collector box, but the ends of my silencers look wider, and it almost looks like they slip over the collector box flanges.
 
SMSW said:
After you clean out the gasket inside those damaged pipes, you might get a heavy round piece of steel and use it like a mandrel to hammer the bent flanges back into their original shape.
Click to expand...
If what I'm thinking is correct, and the exhaust slips into the collector box flanges, I can use a set of big pliers to bend the flanges back into shape, then use the collars to tighten them into the gaskets.
 
Hyper Fish said:
If what I'm thinking is correct, and the exhaust slips into the collector box flanges, I can use a set of big pliers to bend the flanges back into shape, then use the collars to tighten them into the gaskets.
Click to expand...
This is where experience is important. I don't have much (experience) with damaged pipes, but what little I have, has been using a slightly smaller piece of black pipe as the mandrel and tapping away with a hammer. I'd be afraid using pliers/channel locks, etc might distort the cylindrical opening elsewhere. YMMV.
 
Hyper Fish said:
If what I'm thinking is correct, and the exhaust slips into the collector box flanges, I can use a set of big pliers to bend the flanges back into shape, then use the collars to tighten them into the gaskets.
Click to expand...
That's right, just put the gasket on the Muffler and insert into the collector, doing it the other way will destroy/mangle the gasket as you try and squeeze the muffler in. Spread the collector generously to avoid damaging the gasket.
 
You must log in or register to reply here.
Back
Top Bottom