New exhaust won't fit with skid plate?

Discussion in 'Tech Area' started by Waveraider, May 15, 2012.

  1. Waveraider

    Waveraider Member

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    I bought this exhaust off ebay and was pretty happy with it. Problem is my skid plate hits the bottom of the exhaust at the bend. It appears that this pipe drops about an inch lower than the original. Has anyone here made modifications to make it fit, and if so, what did you do?

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  3. dirtbkr188

    dirtbkr188 Active Member

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    Double-check to make sure there aren't two exhaust gaskets in the exhaust port, maybe(?)
     
  4. Waveraider

    Waveraider Member

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    Thanks for the reply, but just one gasket. I can see the pipe itself hangs lower than the original. Somebody's had to of had this problem...
     
  5. Bevelsd

    Bevelsd Active Member

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    Waveraider, do you still have the original exhaust pipe from your old muffler system? I did use one of these Chinese mufflers for awhile and had the same problem as you are have. I ended up cutting off the Chinese pipe and welding on the pipe from my old Honda muffler to get it to clear the skid plate and spark plug guard.
     
  6. Waveraider

    Waveraider Member

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    I still have the old pipe. I guess I can ride this summer w/o the skid plate, and don't ride off-road anyway. I just like the looks of the skid plate on the bike. Thanks for the advise.
     
  7. racerx

    racerx Administrator
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    I'll preface this by stating, in the opening line, that I'm on your side:4: IMHO, the best way around this problem is to go through it...get tough with yourself, bite the bullet and take care of it ASAP. Otherwise, you'll end up living with an unwanted compromise PLUS the growing anxiety that comes from prolonged thinking & re-thinking the situation...the worst of all possible worlds.

    None of the PRC repops that I've run across have had serious fitment issues with a stock motor in place, including what this vendor has been selling over the years. Thus, the needed tweaks are likely to be small.

    Start off by removing the front heat shielding & the acorn nut from the rear mount. This will show you precisely how much clearance you have, or need to gain; it'll also allow you to swing the whole pipe in two directions, while loosely attached at the port end.

    Usually, cutting-down or simply eliminating the stud/nut will provide the necessary clearance. If not, try rotating the muffler inboard. If that does the trick, then it's a simple matter of cutting & relocating the rear hanger. Adding a pair of 0.500" spacers to the lower engine guard mounts may be necessary, or desirable...and virtually undetectable.

    Beyond this, you're talking about some combination of cutting, bending & welding. Don't let's go there until you've tried the easy stuff first. It should work, allowing you to avoid the mental and metallurgical house of horrors :butcher:
     

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