GSX 1100 EF exhaust autopsy

[Cooler]

Hello.
My first post here. Someone on the oldskoolsuzuki.info forum advised me to put some of my questions here as I have higher chances of getting answers.... so... here I am.
I want to know if anyone has done an "autopsy" of the GSX 1100 EF (GS 1150) stock exhausts (the end part with the "filters"). There are some noises coming from my bike's exhausts so I think some filters are "wandering" around and I need to cut the pipes and weld the filters... well not me.. an uncle of mine who has a professional welding machine.
I'd like to know what they contain so I'll know how to cut them. I did such a thing on my previous motorcycle (Yamaha XJ600 type 51j) and had to cut the first exhaust twice as the first cut was not on the right spot. I'd like to avoid that on the Suzana.
I'm aware there are quite small chances of finding such pictures.

About me.. my name is Ciprian , I'm 30 years old and this is me on my motorcycle:

 

[posplayr]

Ciprian
Nice bike. I guess you have figured out by now it is fast. Nice suit, but gloves and shoes are important as well. Good luck on the exhaust. How many miles on the old girl?
No idea about the baffles.
Sorry.
Pos (Jim)

 

[toolman]

nice looking bike ciprian,i have the western version gs1150e.about the exaust i am not exaclty shure but most exaust baffles are either perferated steel or if they do have a packing it will be like a glass fiber sheet. good luck with the surgery on your pipes. hope this info helps.
if i was a betting man i would bet they are the perferated steel.
when you do it take lots of pics we all like pics..........toolman

 

[Cooler]

Well.. this is a picture from the Yamaha XJ600 exhaust surgery
http://www.motociclism.ro/forum/index.php?act=attach&type=post&id=312262
I was hoping someone has such pictures or schemes for my GSX 1100 as the exhaust "ends" look very good and I wouldn't want to spoil them.
I have some nice IXS leather gloves.. I did not wear them as it was hot that day.. and anyway it was just a photo session.
Here's another:

 

[posplayr]

Well,
What I learned even from riding a bicycle is to wear gloves. You can buy vented gloves for the summer, lest you get in the habit of not wearing them.
Good luck, hope you bike is running well.

 

[Cooler]

Well.. I was hoping that someone could give me some "inside" on the "smoking pipes"
The exhaust baffles (filters) have started "singing".. It's like I have some Christmas bells inside my mufflers So I should see about them as soon as possible, although I don't have too much time for the moment.
The old girl has about 46.000 kms, from whom 2000 kms made by me.. I have the bike for 3 months or so.
I still have some hope that someone can give me a little help on the filters (with some pictures).
'bout the gloves: I wear them on EVERY long ride.. I very rarely use the bike for short rides (and most of the short ones are made with the gloves).
Have a good... ride

 

[TheCafeKid]

I think, if you wanted to go this route, and Romania is a far off place to most of us, but you can generally find the exhaust systems for these on Ebay from time to time, even NOS. I see them FAR more often than i do the 1100E exhaust systems...

 

[posplayr]

Romania wow I was figuring Canada, Welcome aboard

Will this at least solve 1/2 of your problem?



http://cgi.ebay.com/ebaymotors/NOS-...6827044QQptZMotorcyclesQ5fPartsQ5fAccessories

 

[Cooler]

Romania wow I was figuring Canada, Welcome aboard
Will this at least solve 1/2 of your problem?

http://cgi.ebay.com/ebaymotors/NOS-...6827044QQptZMotorcyclesQ5fPartsQ5fAccessories

Yes... Romania... Eastern Europe.
Sorry.. the link won't help me.. I don't have too much money.. and anyway I like to repair things if possible as to minimize the pile of garbage I'm producing; yes, I know the exhaust being made of metal is recyclable but still prefer to repair it. The thing is the exhaust ends look VERY good and would be a pity to cut them.
Here's how they look:
-the left one

 

[Cooler]

-the right one:

 

[Cooler]

and finally the front part which looks kinda rusty.. but I'll clean and repaint it when I'll take the exhausts out:

 

[posplayr]

-the right one:

Just like a little peep show :-\\\.

Wondering how to dissect those pipes. It looks like the baffle may be riveted to that end plate which was rolled into the end of the outer skin.

If you have a dremel and cut the end plate out the baffle will likely slide out. You would need to be able to weld it back at the end. Hopefully the other side will just slip out otherwise trouble.

 

[Clone]

Looking at the endcap, it looks as if you could drill the rivets and pull them off so you could get a look at the baffle.

 

[razooki]

Yes... Romania... Eastern Europe.

Where in Romania? I was born in Bucharest but left in '82. Haven't been back since. I guess alot of things have changed since I left. I keep telling my son (who is 6) stories about when I was growing up back in Romania and he doesn't believe me most of the time - he thinks I make this stuff up. Like the fact that we were not allowed to enter the school in elementary if the boy's hair was longer than finger length. Or that again we were not allowed in if we did not bring a certain amount of glass bottles and paper for recycling!! I guess Romania was ahead of the curve when it came to recycling.

If those are indeed rivets you can most likely replace them with screws once you cut them off and remove the baffle.

 

[rustybronco]

Have you located which baffle(s) is (are) loose yet?

Humor me for a moment, I'm just thinking out loud.

put a rod in the the exhaust pipe and press against the pipe to see if you can locate the area of the rattle. then it may be possible to expand the pipe on either side of the baffle with something like this. http://www.sjdiscounttools.com/kdt2071.html

just a thought...

 

[Cooler]

I was born in Oradea, but moved at the age of 5 (1982) to Alba Iulia; I studied in Cluj-Napoca from 1997; right now I'm struggling to finish my phD in electrical machines (motors). I'm an electrical engineer.
As for the baffles at first the right one was making some noises but now the left has started to make noises too so.. I have to open them both. I thought also about removing those aluminium "bolts" but I don't know if I could screw something on them.. would be nice; however the problem might be that the filters could be too large to remove through the other side, as the "tubes" are getting smaller towards the motor.
I wonder if anyone hasn' done anything like this? It could help me quite a lot. I think I'll talke the exhausts down about 2 weeks from now.. hopefully someone could help me.
Have a nice.... ride!

 

[posplayr]

Cooler,
Nice to see you are working on your education. When you say you work on electrical machines do you mean theory of electrical motors/generators or is your emphasis more in the way of controls of such?

Since no one seems to have first hand knowledge of the dissection of the tail pipe (I had a chance on my GS750 exhaust that was hastily discarded) so I will elaborate on my recent experiences with Yoshi exhaust. Yoshi is arguably one of the best of breed; well there is not much to it .

Those rivets are likely holding a flange on the base of the baffle. The end plate was formed with the outer skins. If you drill the rivets the baffle will really be loose but still wont come out . The whole assembly was likely inserted from the wide end and the machine (bent) to close the end.

U will need to cut the end to remove the baffle. Moderate welding skill will be required to restore to any level of cosmetic appeal.

Pos

 

[Stefnwolf]

Cooler,
The whole assembly was likely inserted from the wide end and the machine (bent) to close the end.

U will need to cut the end to remove the baffle. Moderate welding skill will be required to restore to any level of cosmetic appeal.

Best not to cut I think. If it were mine I would grind away the metal at the very end of the pipe where it is bent over the end plate. Grind a little bit at a time and keep stopping and cooling the metal with water. If you don't let it get too hot it shouldn't discolour the chrome. If you do this carefully, it wont damage the end plate (with the rivets on it) either. The whole baffle assembly could then be drawn out and fixed.

The main problem as I see it is welding the end back up will spoil the finish on the pipe.
Maybe this as an alternative?
Make 3 "L" shaped brackets and weld (or rivet, or screw) to the back plate on the inside, positioned on the edge so they slide against the pipe metal.
Slide the assemblies back into the pipes and drill through the pipe and L brackets, and fix with 3 nice stainless headed screws.
Might need some kind of sealer on the end plate, maybe cut a "gaskett" from some aspestos type cloth.

 

[Cooler]

Best not to cut I think. If it were mine I would grind away the metal at the very end of the pipe where it is bent over the end plate. Grind a little bit at a time and keep stopping and cooling the metal with water. If you don't let it get too hot it shouldn't discolour the chrome. If you do this carefully, it wont damage the end plate (with the rivets on it) either. The whole baffle assembly could then be drawn out and fixed.

The main problem as I see it is welding the end back up will spoil the finish on the pipe.
Maybe this as an alternative?
Make 3 "L" shaped brackets and weld (or rivet, or screw) to the back plate on the inside, positioned on the edge so they slide against the pipe metal.
Slide the assemblies back into the pipes and drill through the pipe and L brackets, and fix with 3 nice stainless headed screws.
Might need some kind of sealer on the end plate, maybe cut a "gaskett" from some aspestos type cloth.

Thank you for your suggestion. I think that's how the cans were closed, by plying the outer shell metal over the end cans. It would be very difficult to extract it and weld it back properly. I'll see what I can do.. and maybe consider other's opinions. Maybe someone has by accident an original exhaust in very bad shape and could do an autopsy. That would help me enormously.
Thanks everyone for your input!

 

[Cooler]

Well.. after looking carefully at the back of the exhaust it appears the end round part of the can was forced on the "plied" exterior sheet of metal (the tube part). It was just like a (can't find the word) on a bottle of wine.. Theoretically if I extract somehow the whole pack from the outer "tube" I should be able to weld the edges when I'll put it back in.
What do you reckon?
Here's a newer picture: