The oem muffs on my 89 are on thier last legs. I've repaired them a couple times, but on top of that, they're not even the right ones for my year (the hanger tabs don't line up with the footpeg bracket).
I bought a set of used Kerker slip ons a while ago with swapping out the stockers in mind.
But I never liked the way the Kerkers stick out so far at the back.
So out comes the welder and chop saw:
(https://i17.servimg.com/u/f17/19/98/07/74/0c75d710.jpg) (https://servimg.com/view/19980774/404)
(https://i17.servimg.com/u/f17/19/98/07/74/bf97ab10.jpg) (https://servimg.com/view/19980774/403)
Ah, much better! Thats right where the stockers end.
I still have to add a bracket on the lh pipe to mount the center stand rubber stop.
I didn't like where the intermediate pipes ran either, so I cut them at the base and re-angled them to run closer to the footpeg bracket.
I also took the opportunity to deal with the cans breaking off at the front like some have experienced:
(https://i17.servimg.com/u/f17/19/98/07/74/a124c910.jpg) (https://servimg.com/view/19980774/402)
Welded the mounting tab directly to the can and bolted it through the oem rubber mount in the peg support. Killed two birds with one stone as the can had a hole rubbed through it somehow at that spot. Previous owner damages...
The cans are high enough that I can still get the rear wheel axle out with them installed, but I may have to make a small recess in the back of he LH can in order to keep the axle nut from rubbing with suspension action. I didn't want to push the can out too far and this might be the price of keeping them a bit more "tucked in". Thats a quick and easy fix though. Just a little hammer tap or maybe a scootch of welding.
I still have a little more welding to clean up and a couple brackets, then it's paint the black parts and polish the cans.
Should work out nicely.
Now I have to decide if I want to polish the header pipes or put them black like the collector and Kerker intermediate pipes.
Perfect!
*Exactly* the right thing to do with the Kerker system, weld a tab on the muffler can and support it.
Why?
With the Kerker design (bad design) the muffler can is unsupported and cantalevering off the midpipe.
Kerker does have the midpipe supported but again, the muffler is not.
It's just a matter of time before metal fatigue happens at that soft aluminum slip joint at the front of the muffler can, the joint cracks and muffler can falls off.
This has happened to 3 of us here on the this forum (Alan, Paul and I) and I suspect to several others.
Think of the folks who are riding behind you....
I think we should sticky this and make this a PSA like we do the vacuum petcock safety wire.
***Everyone who has a Kerker 4-1 header or slip ons, needs to weld a support tab to the muffler can or cans***
Thank you for this post GWN, you just may have prevented a serious injury or worse.
Nothing more lethal than an old guy with a welder and a sawzall...
Time for a pop quiz!
What used to be attached here?
(http://fjowners.com/gallery/11/49_22_02_19_8_36_45.jpeg)
(http://fjowners.com/gallery/11/49_22_02_19_8_34_44.jpeg)
A) Your Momma
B) I don't care, it's for the guys riding behind me to worry about.
C) Nothing. These pictures were Photo Shopped, this is FAKE NEWS.
D) High speed slobber valve? :bomb:
It's in the kitchen so-------garbage disposal.
Do I have to lick it to work it out?
You guys are a fucking RIOT!
Roll on down to Stout Sunday week, I'll prove it :drinks:
Just for the heck of it, i threw both sets of cans on the scale. The Kerker slip on's drop 20lbs off the bike.
Not an in in in inconsiderable amount....:)
Repacked the cans. Was just enough fuel in it to start and run for about 10 secs. It is louder, but not obnoxiously so. Doesn't surprise me that they are louder than stock, the Kerkers are essentially just old tech "glass packs". IOW: straight through exhaust.
While I was at it, i removed the Kerker name plates, wet sanded each can and then ran them over the buffer with white compound for a while:
(https://i17.servimg.com/u/f17/19/98/07/74/b34aeb10.jpg) (https://servimg.com/view/19980774/405)
(https://i17.servimg.com/u/f17/19/98/07/74/f3a1e810.jpg) (https://servimg.com/view/19980774/406)
Not bad! Cleaned up pretty good for 30 year old cans!
I didn't go crazy on them, just enough to shine 'em up decently. That's good enough for now. I can always go back over them later on if I want that "flawless" look.
:)
Doesn't sound that bad:
https://youtu.be/gNM3Bd3bi38
A little raspy perhaps, but as I said, they're essentially glass packs. Little echo-y because it's inside the garage, but it should mellow right out once outside. I may experiment a bit with the packing material to see if I like the sound changes. For now, this will do just fine.
:)
Intermediate pipes painted and fit with the FZR1000 EXUP rear wheel installed:
(https://i17.servimg.com/u/f17/19/98/07/74/5e624c10.jpg) (https://servimg.com/view/19980774/419)
(https://i17.servimg.com/u/f17/19/98/07/74/f1cf1310.jpg) (https://servimg.com/view/19980774/418)
I'm really liking how this is turning out! I almost can't wait to tear it down to the frame and do the full restoration!
I like the look of the black so much, I think the header pipes and collector will go black as well. Stock look for this year, but I like things that look stock. Or at least look like they could be stock, even if it is a modified piece.
:)
HI
I my neck of the woods that stand would have come from Princess Auto. Don't leave a bike on the table without the safety shaft going through the holes in the leg I found out the hard way. I wanted the table in a lower position so I could sit on a short stool and work on the primary, the hydraulics will loose pressure and the table will settle to the floor. If something happens to be under the table on one side(JACK STAND) the table will tip and send the whole rig to the floor. Never used the pneumatic feature of the table have no idea if it works. :Facepalm:
Les
Yep, came from PA.
SOP for any jack/lift is to not rely on the hydraulics to hold weight. You need to always use the mecanical lock or a jack stand. But i'm not a fan of how the mech lock works on this rig. I don't like how it holds the "mystery metal" pin in shear.
Planning to build side extensions and a "ladder lock" style stop for it.
The air lift works fine on mine, but it's loud. I actually use the foot pump. It's pretty fast and dead quiet. Maybe 10 pumps from flat on the floor to full raise. I find it more convenient to use the pump than drag out the airline.
My knees and back are shot from 28 years of sar. They hurt, but still work so the foot pump is ok for me, I might feel differently about the air option as my knees get older/worse...:(
Quote from: chiz on February 27, 2019, 08:09:16 PM
..........the hydraulics will loose pressure and the table will settle to the floor.
Les
Like good manners belted into us by our parents, good habits learned as an apprentice became ingrained for life. Never, ever put body parts under something held up by hydraulics alone.
That was hounded into me as a young bloke and I've never given it a thought since, I just do it automatically, every time, even if it's just for a moment. I recall that being caught not doing this incurred quite serious disciplinary measures.
One of the other pearls was "never put your fingers anywhere you wouldn't put your dick!" That has a lot of merit too!!
I have never had a hydraulic lifting device fail in 50 years but I still wouldn't put my hand somewhere dangerous even for a moment if relying on hydraulics alone to support the vehicle.
Many years ago I was called out to advise on lifting options for a Mercedes Benz with collapsed airbag suspension. When this happened the cars sank until the floor pan was resting on the ground. In this case though, a mechanic, someone I had been working along side only an hour earlier had jacked the car up to remove the tail shaft so it could be towed, he was lying under it when the jack let go, the diff got him in the head. I supervised the lift and could not avoid witnessing the extraction of his body. Not that I needed this to convince me, but it was a very sobering demonstration of why we need to play it safe.
Well may you say "the worst that could happen is the bike would fall over" A couple of years ago here in Australia a bloke washing his Harley,
on the ground on it's side stand, had it fall over and the clutch lever went straight through his temple into his brain - and his bike was on the ground!
Noel
Stay safe with the lifting gear guys.
Quote from: ribbert on February 28, 2019, 06:18:42 AM
Quote from: chiz on February 27, 2019, 08:09:16 PM
..........the hydraulics will loose pressure and the table will settle to the floor.
Les
Like good manners belted into us by our parents, good habits learned as an apprentice became ingrained for life. Never, ever put body parts under something held up by hydraulics alone.
That was hounded into me as a young bloke and I've never given it a thought since, I just do it automatically, every time, even if it's just for a moment. I recall that being caught not doing this incurred quite serious disciplinary measures.
One of the other pearls was "never put your fingers anywhere you wouldn't put your dick!" That has a lot of merit too!!
I have never had a hydraulic lifting device fail in 50 years but I still wouldn't put my hand somewhere dangerous even for a moment if relying on hydraulics alone to support the vehicle.
Many years ago I was called out to advise on lifting options for a Mercedes Benz with collapsed airbag suspension. When this happened the cars sank until the floor pan was resting on the ground. In this case though, a mechanic, someone I had been working along side only an hour earlier had jacked the car up to remove the tail shaft so it could be towed, he was lying under it when the jack let go, the diff got him in the head. I supervised the lift and could not avoid witnessing the extraction of his body. Not that I needed this to convince me, but it was a very sobering demonstration of why we need to play it safe.
Well may you say "the worst that could happen is the bike would fall over" A couple of years ago here in Australia a bloke washing his Harley, on the ground on it's side stand, had it fall over and the clutch lever went straight through his temple into his brain - and his bike was on the ground!
Noel
Stay safe with the lifting gear guys.
Yessir, lots of these stories around. So few of them are actually personal stories though.
The "hydraulic lesson" was taught to me in both automechanics training and aviation technician training. Everything had to be "leveled and locked" before going anywhere near it.
But, unfortunately, my first "lesson" in securing something before getting under it came at a much younger age. In my teen years (wow, that was a looong time ago!) i was a "gearhead" along with most of my freinds. One day, I went to one of my freinds house. He had a 454/th400 in a 76 Nova. He had never gotten around to replacing the rearend with anything bigger than the stock 7.5 chevy. Suffice to say, the way we drove at that age; it ate them up like tootsie rolls. But they were cheap, available everywhere and easy to replace so he just kept putting "new" ones in. As I pulled into his parents driveway, something didn't look auitr right. The car had no rear wheels, but it was on the ground. Then I noticed tools off to the side and a coat. I walked up to the car and heard groaning. The car had fallen off the jack and my freind was pinned under it. Sideways and face down. Turns out he had been scooting over to grab a wrench and off the car went. Long story short, he's a quadrapeligic these days and hasn't driven or worked on a car since.
Was months before I would even consider getting a car back up off the ground again. I dare say it was a good year or two before I could bring myself to crawl under a car again. Having to have my freind extracted from under that car that day that shook me up pretty badly at that young an age....and still endures to this day when I have to work under anything.
The "jack-stands everywhere" and "level concrete floor or nothing" lesson was burned into my brain forever that day.
With that lesson solidly in place, my biggest worry these days if something falls over is how much it's going to hurt my wallet....;)
Quote from: chiz on February 27, 2019, 08:09:16 PM
...........the hydraulics will loose pressure and the table will settle to the floor.
Les
I should point out, the same applies for mechanical jacks.
Noel
I like doing service on my cars and bike myself byt on my latest car i think its a nightmare because the oildrain plug is almost in the middle under the car under a plastic cover.
Before i used to go to a D.I.Y drive in where i could just drive the car into a carlifterramp and stand upright under working.Those places are now totally gone here in Norway so now i have to
lay on my back on the ground (working on a deserted parking place ) with all my body under the heavy car to do work.I use 2 small ramps that i drive the car upon then i secure it with 2 carstands and a piece of wood behind the rear wheel.
Still i dont feel real safe laying under there draining the oil.
Got the "farm tractor" out in the sun today for a wash off and took a quick vid of how it sounds with the Kerkers outside:
https://youtu.be/bVbZYfeza2w