- Joined
- Dec 3, 2009
- Messages
- 22,443
- Reaction score
- 262
- Location
- Van Nuys Ca.
- My Bike Models
- 1983 Interstate
2018 KLR 650
2018 BMW S1000 RR
- My Bike Logs forum link
- https://classicgoldwings.com/forums/dan-filipi.122/
I've had the mufflers off for various reasons, 2 engine swaps, testing and experiments with other exhausts etc.
Every time I do it I need help or if I don't have help I finish the job in a rotten mood after fighting them to line up and holding the weight while starting the bolts. I figured out a easier way this last time so I documented it.
If done in this sequence it's pretty simple.
The difficulty is because the 1100 has a crossover pipe. If that wasn't there I wouldn't be writing this.
With both mufflers on the ground and separated from the crossover pipe, the right hanger should be removed from the muffler. The left muffler hanger should be bolted to the muffler.
Pull the old gaskets out of the head if your replacing them. They pop right out with a flat screw driver under the edge. I would replace whenever pulling the exhaust to ensure a leak free seal.
Clean the head seal with a wire wheel in a drill and make sure the exhaust pipes seal surface is clean and flat.
(I had the studs removed in the first picture because someone had installed them upside down. Short thread end goes into the head otherwise the nut will run out of threads when tightening and leak)
Not a bad idea to also clean the crossover clamp inside and the sleeve.
Now lift the left muffler into place and slide the hanger bolt thru the frame hole into the hanger bracket and start the nut on but don't tighten yet.
Next, lift the head end up so the studs just start into the header leaving enough room to slide the seals into place.
This step is important because the seals are VERY soft and damage easily if one of the studs hit them or go in cocked. Been there.
With the seals in place, carefully lift the head end up watching the seals don't slide out of position, then put the 4 nuts on. Dont tighten yet beacause we need some flexibility in this muffler for the next step.
Now, with the left muffler in place and nothing tightened down, prep the gasket surfaces on the right side like done on the left.
The hanger bracket should NOT be on this muffler at this point, if it were we wouldn't be able to do the next step.
Lift the right muffler and first insert the crossover with a push and twisting motion.
It should go all the way in to a stop and look like this.
Now lift the head end up, start the flange into the head bolts, and slide the seals into place.
Start the 4 bolts.
The reason nothing is tightened at this point is we want to make sure we get a good seal at the heads.
The head flanges need to line up straight into the head and squish the seals evenly.
The way this is done is to EVENLY tighten the 4 head bolts.
I like to push the pipe up as far as it'll go then seat the nuts and alternate between the 4 as the pipe is pulled EVENLY up until all 4 are tight. If the flange goes up crooked the seals may get squished wrong and leak.
Once that's done on both left and right headers the right hanger can be put in place and bolted on starting with the 2 bolts onto the muffler.
I had a problem with mine where the thru bolt into the right bracket wouldnt line up.
I had to ream the hole in the bracket.
Once that bracket and all bolts are in place everything can be tightened.
Don't forget to tighten the crossover clamp.
I hope my tip makes someones life just a little bit easier, it sure did mine.
Chrome polish on:
After buffed out:
Every time I do it I need help or if I don't have help I finish the job in a rotten mood after fighting them to line up and holding the weight while starting the bolts. I figured out a easier way this last time so I documented it.
If done in this sequence it's pretty simple.
The difficulty is because the 1100 has a crossover pipe. If that wasn't there I wouldn't be writing this.
With both mufflers on the ground and separated from the crossover pipe, the right hanger should be removed from the muffler. The left muffler hanger should be bolted to the muffler.
Pull the old gaskets out of the head if your replacing them. They pop right out with a flat screw driver under the edge. I would replace whenever pulling the exhaust to ensure a leak free seal.
Clean the head seal with a wire wheel in a drill and make sure the exhaust pipes seal surface is clean and flat.
(I had the studs removed in the first picture because someone had installed them upside down. Short thread end goes into the head otherwise the nut will run out of threads when tightening and leak)
Not a bad idea to also clean the crossover clamp inside and the sleeve.
Now lift the left muffler into place and slide the hanger bolt thru the frame hole into the hanger bracket and start the nut on but don't tighten yet.
Next, lift the head end up so the studs just start into the header leaving enough room to slide the seals into place.
This step is important because the seals are VERY soft and damage easily if one of the studs hit them or go in cocked. Been there.
With the seals in place, carefully lift the head end up watching the seals don't slide out of position, then put the 4 nuts on. Dont tighten yet beacause we need some flexibility in this muffler for the next step.
Now, with the left muffler in place and nothing tightened down, prep the gasket surfaces on the right side like done on the left.
The hanger bracket should NOT be on this muffler at this point, if it were we wouldn't be able to do the next step.
Lift the right muffler and first insert the crossover with a push and twisting motion.
It should go all the way in to a stop and look like this.
Now lift the head end up, start the flange into the head bolts, and slide the seals into place.
Start the 4 bolts.
The reason nothing is tightened at this point is we want to make sure we get a good seal at the heads.
The head flanges need to line up straight into the head and squish the seals evenly.
The way this is done is to EVENLY tighten the 4 head bolts.
I like to push the pipe up as far as it'll go then seat the nuts and alternate between the 4 as the pipe is pulled EVENLY up until all 4 are tight. If the flange goes up crooked the seals may get squished wrong and leak.
Once that's done on both left and right headers the right hanger can be put in place and bolted on starting with the 2 bolts onto the muffler.
I had a problem with mine where the thru bolt into the right bracket wouldnt line up.
I had to ream the hole in the bracket.
Once that bracket and all bolts are in place everything can be tightened.
Don't forget to tighten the crossover clamp.
I hope my tip makes someones life just a little bit easier, it sure did mine.
Chrome polish on:
After buffed out:
