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Buell Motorcycle Forum » Old School Buell » Archive through December 17, 2009 » Link for "proper" way to mount exhausts? « Previous Next »

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Brinnutz
Posted on Tuesday, November 17, 2009 - 11:51 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Hey guys, I can't figure out why, but the search is not working for me and am trying to help show a buddy how to mount his exhaust properly.

Anyone have a bookmarked link?

Thanks.
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Texastechx1
Posted on Tuesday, November 17, 2009 - 12:41 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

x1files?
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Ratbuell
Posted on Tuesday, November 17, 2009 - 12:58 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Hang everything in place, nuts on fingertight so everything can still move around. Header to heads; collector to hangar; muffler to collector; rear muffler to hangar.

Start at the heads. Torque to spec as you wiggle the components while they seat to the seals.

Then torque the collector to the hangar.

Then torque the muffler to the collector (don't forget copper RTV at the seal; a dry coupling will leak "pfft pfft pfft").

Then torque the muffler to the rear hangar.
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Dave_02_1200
Posted on Tuesday, November 17, 2009 - 01:00 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

I want this information too and for good reason: Today I found out that a friend with an X-1 crashed hard last week when his race muffler broke free at the front and contacted the ground.

He is out of the hospital but is still recovering so I have not heard his explanation of what happened and I have not seen the bike so I don't know exactly what broke or why.

I want to come up with a preventative measure to keep this from happening again on his X-1 or on my M2 or S3. Maybe a retaining strap, belly pan or some other back-up measure could be devised in case the mounting system fails.

Any information or advice regarding this would be most appreciated.
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Daveswan
Posted on Tuesday, November 17, 2009 - 01:04 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

This is a service bulletin for the retrofit, does it help or do you need something else?

http://badweatherbikers.com/buell/bulletins/Exhaus tMount95-00.pdf
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Ratbuell
Posted on Tuesday, November 17, 2009 - 01:14 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

That's for a stock muffler.

There is one somewhere specifically for the race muffler; it consists of a short cable "leash" that you rivet to the front of the muffler can at one end, and attach the other end to a primary cover bolt. I have one on each of my race-muffler'd tubers.
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Daveswan
Posted on Tuesday, November 17, 2009 - 01:18 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

race muffler retention kit

http://www.badweatherbikers.com/buell/messages/384 2/B034-263581.pdf
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Ratbuell
Posted on Tuesday, November 17, 2009 - 01:23 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

That's the one.
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Dave_02_1200
Posted on Tuesday, November 17, 2009 - 02:23 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Dave and Joe,

That is exactly the information I needed.

Now I can make a suitable retention cable to keep that from happening again.

Thank you very much.

Dave
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Gbackus
Posted on Tuesday, November 17, 2009 - 03:27 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

What is the torque specs on the headerbolts?
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Ebutch
Posted on Tuesday, November 17, 2009 - 04:07 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Nice Work David Swanson!!!!
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Daveswan
Posted on Tuesday, November 17, 2009 - 05:47 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Gee thanks... glad to actually be of assistance. I know you people have helped me so it's only right to return the favor if I can.

Torque specs for header bolts are pretty low:
6-8 ft-lbs or 72-96 inch pounds.

Depending on which torque wrench you're using.
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Sloppy
Posted on Wednesday, November 18, 2009 - 11:41 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

On Race Muffler;
My understanding is that there are TWO versions of the race muffler. One that requires the catch strap, and another that has an additional spot weld on the inlet that DOES NOT require the spot weld. Where does the race muffler fail?

On header installation;
I actually torque the bolts from the BOTTOM up. Idea being that TOP down, puts all the weight of the exhaust on the head studs. By installing from the BOTTOM up, the other fasteners hold the mass of muffler and header and thus the exhaust studs just locate the header into the exhaust manifold. This procedure also helps identify IF you have a twist in the header. It does appear though that BOTH procedures work...
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Andymnelson
Posted on Wednesday, November 18, 2009 - 12:08 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

If the issue is stress on the components as it is tightened up, my engineer brain would say that the following would make more sense:

Finger tight everything, except the clamp- leave the clamp very loose.
Tighten header to proper torque specs.
Tighten muffler to proper torque specs.
Tighten clamp to proper specs.

I would think that torquing the clamp before the muffler would place a stress on the collector and therefor the header bolts? Or is the idea here that there is enough play in the muffler mounts that you can tighten the clamp first, which positions the muffler in the correct place and you tighten it down there? Man, if that's the case, it would be very important how you tighten the muffler mounts so that you do not move the muffler around at all while torquing it...almost impossible to do I would think.
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Jayvee
Posted on Wednesday, November 18, 2009 - 12:10 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Sloppy, I'm not sure about the physics on your sequence, wouldn't the head studs still only hold the 'weight' from the studs to the next attachment point, regardless of the sequence in which they are tightened?

In any case, I'm confident either way would work, as you suggest.

If it really mattered, how would you remove and replace JUST the muffler, as so many service procedures require? On my recent muffler re-install, I started at the collector, then front mount, then rear mount. Not to imply that's the 'right' way...


(Message edited by jayvee on November 18, 2009)
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Sloppy
Posted on Wednesday, November 18, 2009 - 01:01 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

LOL - this is definitely "fuzzy" physics as we don't know all the variables involved. In this case we have stresses due to changes in length, vibration in the vertical plane and harmonic vibration of the muffler due to exhaust flow and frame movement. And of course there are other variables involved, but the order of magnitude is unknown.

I should have clarified that in my case I am using the RACE muffler, which has floating mount points for movement. This may be why my methodology works? Since the RACE muffler isn't a fixed mount point I don't need to re-mount the header when it gets removed.

I think the important thing is to make sure the system is torqued in a sequential method.
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Ebutch
Posted on Wednesday, November 18, 2009 - 08:23 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

I do have spot of weld on intake so holding collier can not slip off.Got my race can from e-bay and arare bird it is not stainless steel but aluminum!!!
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Ebutch
Posted on Wednesday, November 18, 2009 - 08:38 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Just went to shed and looked at muff. and spot of weld is close to muff body so it can not hold collar on header but it is latter muff with weld and is a rare bird aluminum race can! heres another pic

(Message edited by ebutch on November 18, 2009)
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Ebutch
Posted on Wednesday, November 18, 2009 - 09:14 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

I didn,t think header and can where so critical but will pay more attn to every thing!!! It could make me be around longer!!

(Message edited by ebutch on November 18, 2009)
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Sloppy
Posted on Thursday, November 19, 2009 - 12:08 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Aluminum race can? Never heard of it, but the race muffler is HEAVY in steel. Shouldn't be too hard to get a sheet of aluminum and roll it into shape to replace the steel. Hmm...

I'm thinking that the spot weld is there to reinforce the inlet to the muffler - perhaps the failure was at the weld of the inlet pipe to the can? And the spot weld reinforces the weld?
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Ebutch
Posted on Thursday, November 19, 2009 - 01:16 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Heres a pic of weld spot Sloppy.
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Ebutch
Posted on Thursday, November 19, 2009 - 01:18 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

hmmmm I mean spot welds
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Ebutch
Posted on Thursday, November 19, 2009 - 04:05 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

I,ve had stainless steel can sounds tinny hollow sound.Aluminum can sounds not tinny and much less hollow.and a dime in thickness of alum flat stock.

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Mrsteam34203
Posted on Wednesday, November 25, 2009 - 04:09 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

my 1999 x1 race muffler broke off clean at the front,frount muffler clamp still on. the can dropped at 60 mph sending me and the bike forward. Broke my feet,toes,my shoulder, lots of road rash,Thinkful I was wearing a helment. The bike can be fixed. I am looking for race muffler , witch will be secured.If anyone has one please let me know, Thanks .
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Buellistic
Posted on Wednesday, November 25, 2009 - 07:28 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Have a paragraph on PROPER EXHAUST ASSEMBLY ...

It is yours by request, just e-mail me so that "i" can get your e-mail address ...

On these race mufflers, you need to have a strap(stranded wire) looped under front and rear on muffler because they are notorious for breaking ...
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