Fitting the standard exhaust system

[PaulD]

When I bought my Kat the bike was fitted with a new 4-1 Jama zorst with stainless down pipes, it also came with a standard system that had been refurbished to a good standard. Now as nice as the Jama is I don’t really like 4-1 exhausts because in my mind they make the bike look unbalanced so the plan all along was to refit the standard system at some point.
Looking through the parts book the three pieces are joined with two clamps and two odd looking seal thingymebobs which where missing from the system. Suzuki vintage parts sell the seal doofas for £28 each! you need two plus the two clamps, that’s over £100 just to fit the standard exhaust so I put it on the to do list. I was in the shed the other day looking for summat and lo & behold in the box of spares I got with the bike are two brand new and bagged seals & clamps! Guess what I’m doing tomorrow

[PaulD]

I’ve spent a wasted three hours in the garage today and I’m buggered if I can get the standard exhaust to fit? First off I tried fitting the inner section loosely and then the two outers which looking at the way the system is designed is the way to do it but for the life of me I couldn’t get everything to line up. Then I fitted the outers and tried to fit the inner but no go. I even assembled the whole thing and then tried to fit it to the bike but it’s not a job for one man on his own. So for now the Jama is back on with new copper gaskets. I’m in two minds wether to try again or just live with the Jama and sell the standard exhaust to free some funds up for my ongoing T500 resto?

[KeKat]

Hi i assemble the whole exhaust. Put some cardboard underneath the bike, then slide the exhaust system under the bike. next i use bungee cords to hold up the silencers in place, this allows you to move the headers in to the ports, while keeping the silencers parallel Also a small hydraulic jack can help on the collector box.

I have done this job many tines by myself.

Hope this helps.

[PaulD]

Brilliant, thanks for that. I’ll give it a go next weekend and let you know how I get on.

[PaulD]

Well I’ve assembled the whole system ready to attach it to the bike. I’ve got new clamps and joint seals fitted ready to go. I paid particular attention to lining the downpipes up and making sure they are all leve where the fit into the head. Unfortunately rain has stopped play today so the big moment will have to wait for now. I’ve attached a couple of pics showing the system which the previous owner has nicely repaired and refinished.

[Uncle Bob]

Do you know how they were refinished? They look nice. I would have stored them and kept the 4-into-1 one, much better sound, but each to their own

[fossie]

Must ask why store them?

[Uncle Bob]

If / when selling time comes you know how people (not KoC members!) love to pay more for that original look! I prefer my stainless Eagle on the bike but have my set of 4 into 2 wrapped up in the loft where they aren't losing me any money.
I'm sure there's isn't anyone on here that doesn't have some parts stored either for if something wear's out, to put back to original or just cause they might need them at some point

[johnr]

storing unused motorcycle components in the loft is ridiculous, i dont know why anyone would do such a thing......................................................................................





just evict your children and then keep your spares in their bedroom, that way you can keep it warm with a radiator and tuck it in snuggly at night......

[johnr]

finish looks lik ceramic coating, fab stuff but can be prone to turning grey after a bit of use, particularly the downpipes.