Replacing a Muffler on a GS850g

[Anonymous]

Has anyone replaced the mufflers on an 850 but still used the original pipes? I'm tired of more exhaust coming out of the middle than the ends.
JC Whitney carries quite a few types, but I'm concerned whether they'll fit over the "2 into 1" part that goes into the exchange.
Thanks,
Steve
1980 GS850g

[Anonymous]

muffler for GS 850

I have an 82 GS 1100GL. I recently installed two universal megaphone mufflers on my bike and was very pleased with the results. The mufflers are 23 inches long with a 4 inch megaphone end. They are slightly longer than stock but look and sound great. I paid only $58 dollars Canadian ($ 40 U.S). They were made by Mac exhausts and are available from a multitude of sources. I won't lie to you, they were a tight fit but they did fit. The muffler end is expandable or contractable through circular metal sleeves which are included. I also suggest you retain the original muffler shields although you may have to gently bend them so that they conform to the different dimensions of your new mufflers.

[shaftzuki]

I've also just recently replaced the mufflers on my gs1000g - I was also concerned about the 2 into 1 merge, but after a small amount of "surgery" I was able to fit a new Dunstall replica muffler on both sides. Your mufflers (if there like the 1000's) are comprised of an inner and an outer pipe - just after the 2 into 1 you'll see a weld that runs completely around the pipe, this is where you can separate the old muffler from the inner exhaust pipe by using a hacksaw to cut through the outside pipe on the downstream side of the weld. Once you've cut all the way around (be careful not to cut into the inner pipe) you should be able to slide the muffler casing back (or off, depending on how bad they are) - you can then measure a couple of inches to rear and cut the inner pipe off. Make sure you clean up the edges with a file. The pipes I purchased have 1 5/8" inlet size but also come with collars to reduce the size if need be. You can retain your stock look and add one of several aftermarket mufflers available - keeping the 4 into 2 is great (and it's MUCH cheaper than stock replacements). Sorry it's so long winded - send me an email and I can send you photos or a "longer" description". Good Luck!

[Anonymous]

Replacing a Muffler on an 850g

Thanks for the ideas. I'll let you know how it turns out.
Steve
1980 GS 850g

[Anonymous]

I ordered the Megaphone w/upbend from JC Whitney for my 850. I had a buddy (who is a welder) cut the old phones off where they come out of the 2 into 1 area. Next I had a local machine shop cut me 2 each 6 inch pieces of muffler pipe (1 7/8 or 2 inch if I remember right). Welded on the extensions to the original "header/crossover combo" and slipped the phones from whitney right on. They had to be necked down quite a bit, but they did come with the neccessary stuff to do just that. Its been quite a while now since I did that and they work pretty good. Could be better, but I can't complain for the price. Around $100 total.