I am struggling getting the exhaust to connect to the hanger, my bike is an 85 K I have a 87 exhaust a later foot hanger without the rubber bushes and I can't get the mounting holes to line up. I have made a plate welded to the later type exhaust bracket but you can see from the photo the exhaust is about 50mm closer to the engine than it should be. Were the earlier bikes fitted with slightly shorter exhaust pipes, because I have difficulty getting the clearance to fit the clamps and there are problems with the side stand as well.

I was thinking of grinding off the exhaust bracket along the black line in the picture to get slightly better clearance



Any other ideas before I start grinding?

Ali

That looks to me like it needs the later type of rubber mounting, if anything maybe the exhaust is 10-15 mm too high which would just push down.

I have the later type mount which I have welded a plate on to let it line up with the original mounting hole on the exhaust

I've been struggling with a similar problem, a one-bolt muffler and two bolt foot plate.
Have you tried loosening all the clamps on header pipes at the plenum and then moving the muffler around? It's a two-part process. First, assemble the heat guard and foot plate before tightening the header clamps. Second, remove the plate and heat guard again in order to tighten the final header clamp before re-assembing the same. Doing the above I got the assembly within 3/8"--not perfect but fairly close for final clean-up with a Drammel.

I have tried that when I pull it back to line up the hole it comes off the pipes, that's why I am beginning to think the pipes are the source of the problem.

Are you mounting it with or without this bit?

Yes it's that mount I have welded a metal plate to extend the mount towards the exhaust bracket

May have been in a bingle which made things a bit cockeyed but they are all the bits needed.

Here are some pics of how it is mounted with the welded plate





Still got clearance issues at the clamps on the exhaust pipes though.

Ali

Think I have got to the bottom of the problem. I have bought another set of down pipes from an 84 K 100 RS and these are about 2 inches longer! Looks like the PO had cut the original pipes for some reason. Now the fun begins taking of the exhaust nuts!!

Ali

Good detective work Ali! Sounds frustrating but be good when you get it sorted
Cheers
Dave

Ali,
Maybe the PO couldn't get the silencer off........so he cut the pipes instead?

Paul

Possibly, he did have the silencer hanging by a piece of building block work strap, so anything is possible.

spray the nuts and let them soak for at least 12 hours ali

respray if you can a few times ...wd40, rp7, anything

Just to give an update, managed to get 7 nuts off with a little help from a great rounded nut removal tool, but one stud snapped of bugger!! As you can see from the picture below the PO had shortened the pipes for some reason hence the problem getting the clamps and exhaust on.



Ali

Good result Ali.

I'd be unable to resist buffing them up now that they're all apart like that.

I'm trying!! Still thinking how to get the broken stud out, it would be one next to the engine with limited space to work in!

How much of the snapped stud is left?

It snapped flush with the flange so about 15-20mm maybe, was thinking of getting the cam type stud extractor or the impact stud remover like this.

http://www.ebay.co.uk/itm/1-2-IMPACT-STUD-EXTRACTOR-REMOVES-6-13mm-BOLTS-STUDS-/120924407829?clk_rvr_id=476402916299&mfe=sidebar

http://www.ebay.co.uk/itm/1-2-IMPACT-STUD-EXTRACTOR-REMOVES-6-13mm-BOLTS-STUDS-/120924407829?clk_rvr_id=476402916299&mfe=sidebar

http://www.ebay.co.uk/itm/SEALEY-VS7232-STUD-REMOVER-EXTRACTOR-INSTALLER-6-19MM-FOR-1-2-DRIVE-/310500479481?clk_rvr_id=476396196483&mfe=sidebar

That last type will probably be too bulky to use in the space you have.

You'd be better trying something like these:



http://www.amp-starters.co.uk/product.asp?P_ID=1149

I have a set, they're relatively small and simple to use.

Shame you are at the other end of the country, you could have borrowed mine.

Saw something like that, is it 8mm stud?

They are 6, 8, 10 & 12mm and they work on a cam-roller system; as you turn, they grip more. They are ½ inch drive.

A bit of heat and Bob's your proverbial.