Kerker slip ons, with a twist!

[great white]

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:





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:



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.

[Pat Conlon]

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.

[ZOA NOM]

Nothing more lethal than an old guy with a welder and a sawzall...

[Pat Conlon]

Time for a pop quiz!

What used to be attached here?





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.  

[racerrad8]

D) High speed slobber valve? 

[TexasDave]

It's in the kitchen so-------garbage disposal.

[Troyskie]

Do I have to lick it to work it out?

[ZOA NOM]

You guys are a fucking RIOT!

[Troyskie]

Roll on down to Stout Sunday week, I'll prove it 

[great white]

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....

[great white]

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:





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.

[great white]

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.

[great white]

Intermediate pipes painted and fit with the FZR1000 EXUP rear wheel installed:





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.

[chiz]

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.
Les

[great white]

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...