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plugging punched out exhaust

jsandidge

jsandidge

Forum Sage
Past Site Supporter
It appears the PO punched out holes on the plate at the back of the mufflers on my 83 750E. I'm assuming only the center hole should be open, and the 6 outer "holes" should not be open. I get some sputtering and popping on decel that I think is related to this. Has anyone successfully plugged holes like this? What did you use? Welding is not an option for me.
 
Look closely before you decide which holes were originally open. I have seen some bikes that had just the center hole open and some that only had the outer holes open. I have not seen any that had all of them open.

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The outer holes are not completely round, which leads me to believe they were tampered with. There is also no raised "tube" around any of the outer holes, which is unlike my 850. My 850 has only the center hole open.
 
Could you thread the holes and put in button head cap screws.
Or pipe tap with pipe plugs screwed to almost flush.
 
I have used some steel epoxy putty with modest success. If you can reach through the center hole and get to the back side of the outer holes, it's even better. Mix up some putty, press it through the holes. If you can reach the back side, smash it down a bit so it's larger than the hole and won't come back through. Continue packing some putty on the outside, so it is larger than the hole, too. When it sets, you can use a small sanding tool to smoothe out some of the irregularities, then paint it all black. Very few people would notice it if you didn't point it out.

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I bet with a little bit of effort and 'noodle power' you could fashion up a donut type stainless steel ring that would cover everything, maybe use a thin layer of exhaust matting to seal everything up? a few nice stainless steel allen head screws to hold it all in place.
 
I wound up getting some hole 3/8" hole plugs and secured them in with the JB Weld putty. The bike sounds soo much better. It seems the sputtering has cleared up too. I need to take it for a ride to be sure, but it's raining cats and dogs right now.

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