TOPIC:

Hey guys, I am completely new to the forum. I recently purchased a kz1100 and I'm working on getting it up and running again. Currently it has a 4 into 1 Kerker exhaust and the muffler on the kerker looks terrible. I was wanting to replace it with a slip on, but the muffler is welded to the head pipe. I should also mention I am a total newbie and this is the first mechanical type project I have ever done. Any suggestions on being able to replace that muffler?

How about a pic of the other side and a pic of where it's welded.


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Yes. Rather than being clamped it is welded and I want to change it. I'm just curious what the best approach would be.

Possibly cut off the muffler and add an extender to attach a new muffler.

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I would use the new muffler as a template before cutting. Check the ID & OD of everything, including the spacers, before making the cut.

An extender might be available at an auto parts store, but the best bet is probably a muffler shop.
The muffler shop guys may be willing to cut off the old muffler as well as prepare an appropriate size extender.
In any event, both the header (collector) and old muffler should be on hand for measuring incident to preparation of an appropriately sized extender.

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Awesome. That is immensely helpful. Now, do you have any advice on the actual process of cutting the muffler? I am trying to do everything by myself on this bike without having to take anything anywhere. We'll see how that turns out.. ha!

If you need to acquire any parts for your exhaust system check out the folks at the link below. They sell nearly anything you can imagine related to motorcycle exhaust parts. You may need to cut and paste the link into google since clicking on many links from KZRider yields error messages. Ed

www.coneeng.com/motorcycle_components.html

Hack-sawing off the muffler will unavoidably take some of the collector with it, thereby shortening the length of the collector.

Perhaps find a section of pipe having an outside diameter that fits snugly into the collector and protrudes enough to accept the new muffler.

Could apply high temp copper sealant to semi-permanently seal and secure the section of pipe where it fits into the collector, which basically extends the collector with an effectively smaller o.d., which protruding extension will require shimming wrap or packing (or some other heat-resistant material) to achieve a snug fit into the new muffler.

Do NOT use sealant where the muffler connects, because the muffler needs to remain adjustable back and forth and rotationally in order to achieve correct positioning for chassis and hanger compatibility, and to be removable. That's the purpose for the clamp.




Good Fortune!