Holes in my Mufflers..Recomentations on what to replace with

[derwood]

get some Harley Davidson stock takes offs, they are probably nicer than the ones in the first link. cheaper too, even in NZ

[650Skull]

get some Harley Davidson stock takes offs, they are probably nicer than the ones in the first link. cheaper too, even in NZ

They aren't that cheap over in NZ although they can pop up occasionally,The Harley pipes have their own problems that involve extra cost and I'm not into their look. Found some others mufflers today for just over $120 each and that's with the ride from the US.

[Wingsconsin]

IF you were in the USA I would tell you to check with any Harley Davidson dealership -
They typically have a number of take off mufflers in the service shop waiting for a need -
It seems the HD gang like to 'upgrade' their bikes to louder pipes to save lives --
Harley is really good at chrome

[Grimly]

IF you were in the USA I would tell you to check with any Harley Davidson dealership -
They typically have a number of take off mufflers in the service shop waiting for a need -
It seems the HD gang like to 'upgrade' their bikes to louder pipes to save lives --
Harley is really good at chrome

I, for one, applaud their Public Safety Initiative, as long as it stays well out of my area.
I like buying Fat Bloke mufflers by post.

Shocks too. Recently scored another perfect set of Showa air shocks from the back of a Fat Bloke for relative peanuts.

[metalfab]

Do you have any motorcycle recyclers/salvages in your area. All exhausts don't age the same, it is possible to find really great used stock exhausts sometimes. I say this with the thought in mind that any exhaust that isn't factory will likely need some degree of adapting. And that can be a lot of surprises, sometimes replacements just wont fit because of many reasons. Then there is the fact that something different can look fugly or odd once it is in place. I am not trying to discourage modifying it, I am saying think through the negative possibility's before you spend money. I have learned this lesson over and over.

[650Skull]

Another angle
thumbnail_image0,.jpg

[650Skull]

Another solution. Collar welded to the double walled header pipes on my 83XS650
thumbnail_image0.jpg

[650Skull]

Final fitting..........slip the small end of the adapter, over the inner pipe, under the outer pipe, Tight fit. Slip the muffler over the adapter and but up to the chrome header and fasten This should make a good seal with no leaks
muffler2.jpg

[650Skull]

Reducer/Adapter
adapter.jpg

[650Skull]

Header pipe from a XS650 Special, with the muffler cut off. these models had a full header/muffler, one system, from the factory

inner.jpg

[650Skull]

Under the exhaust, to the far left, showing where the heat shield bolts on around the area where the header and muffler meets i think.
thumbnail_image8e.jpg

[650Skull]

Series of pics showing the exhaust and solutions to cutting the muffler off the double walled headers

Semantic of the whole exhaust
MjEzMDcxMQ-a261b573.jpg

[650Skull]

@ metalfab Yes, you bring up all the points that can be problematic in this situation. No, on the bone yards, these models are thin on the ground as is and i don't even know if they were factory sold into NZ. This bike was imported by the PO about 3 or so years ago from Canada.



Yes i am aware the headers are double walled and cutting the factory muffler off the header the inner pipe has to be made to connect a slip on Muffler. Then made to seal so the exhaust fumes won't go back between the inner and out pipes on the header.

there are 2 ways to do this. Getting the right reducer/adapter that slips over the inner pipe from the header and expands so the slip on muffler goes over the large end of the reducer/Adapter. These come in different sizes.

Shows in sequence in Posts #25,#24,#23

The second way is to weld the inner and outer pipes together and weld a collar on so a slip-on muffler can be used. Post #22, #21

Making it suit, (as in looking close to original or just good), is an issue as the GS650E exhaust had a small heat shied bolted to the header where it expanded out to the Muffler. Where to cut is also and issue as i haven't had any experience with these.

If someone has done this before i would be very grateful to hear how it was done and some measurements on where the best place is to cut