Airhead Muffler Mystery

In article , Rob
Kleinschmidt wrote:

> On Apr 9, 9:35 am, SaltineDawg wrote:
> > I bought a new muffler off eBay, as the former one broke off while
> > riding.
> >
> > I undid the clamp on the header pipe that was holding the broken end of
> > the muffler and had to chisel off the remainder. Seemed to go okay.
> >
> > But now the new muffler won't slide on there far enough. Inside the
> > muffler outer housing is another, slightly smaller diameter tube, inset
> > from the end of the muffler housing about 1/2"... and too small to
> > slide up over the header pipe.
>
> Some mufflers use a soft metal gasket between a pipe
> and collector box or muffler. My bet would be that you've
> got some kind of shim or gasket that's been pushed
> partway into the muffler.
>
> If you've got a local dealership, ask the parts guy
> nicely if he can show you the diagram for the muffler
> assembly. My bet would be there's a stock gasket.
>
> It's also possible that somebody kluged this together
> trying to fit the muffler onto a pipe that was smaller
> than stock.
>
> In any case, I'd see if I could use some kind of hook
> thingy to fish the sucker out. I doubt it's fastened in.
> Auto parts stores can sell you a cheap set of hooks
> and picks that would likely do the job for you.

I don't think so. The muffler looks right. That inside inset piece
appears to be properly manufactured and completely integrated with the
muffler... not just a gasket or whatever.

It just doesn't fit the header tube.
 >> Stay informed about: Airhead Muffler Mystery 

On Apr 9, 8:16 pm, SaltineDawg wrote:
> The muffler looks right. That inside inset piece
> appears to be properly manufactured and completely integrated with the
> muffler... not just a gasket or whatever.
>
> It just doesn't fit the header tube.


If you don't think it's a pushed in metal gasket, then you
need to consult a parts diagram.

The diagram at this site is for a different model airhead,
but shows the kind of parts I'm talking about:

http://www.xmission.com/~wendell/GS/node48.html

The metal parts # 7, 8 and 10 are shown as "gasket". I think
what you're looking is a similar metal gasket pushed all the
way into the muffler.

If it's not a gasket and it really is integral, then you're apparantly
trying to put mismatched parts together and you need to
consult with a parts CD and/or parts guy to figure out the
right parts.

A good parts diagram will tell you what parts you
ought to be working with and offer some clues about how
the stuff fits together.

I wish you the best of luck but don't have anything more
to suggest.
 >> Stay informed about: Airhead Muffler Mystery 

In article , Rob
Kleinschmidt wrote:

> On Apr 9, 8:16 pm, SaltineDawg wrote:
> > The muffler looks right. That inside inset piece
> > appears to be properly manufactured and completely integrated with the
> > muffler... not just a gasket or whatever.
> >
> > It just doesn't fit the header tube.
>
>
> If you don't think it's a pushed in metal gasket, then you
> need to consult a parts diagram.
>
> The diagram at this site is for a different model airhead,
> but shows the kind of parts I'm talking about:
>
> http://www.xmission.com/~wendell/GS/node48.html
>
> The metal parts # 7, 8 and 10 are shown as "gasket". I think
> what you're looking is a similar metal gasket pushed all the
> way into the muffler.
>
> If it's not a gasket and it really is integral, then you're apparantly
> trying to put mismatched parts together and you need to
> consult with a parts CD and/or parts guy to figure out the
> right parts.
>
> A good parts diagram will tell you what parts you
> ought to be working with and offer some clues about how
> the stuff fits together.
>
> I wish you the best of luck but don't have anything more
> to suggest.

Thanks for all your attention, info and help.

The only other thing I can think of here is that, at some point, the
entire header pipe assembly had been changed, using one from some other
model/year with a slightly different diameter.

All parts involved *look* correct, as is. But they're just not fitting
together right with this new muffler, which *is* the correct part for
this year/model.
 >> Stay informed about: Airhead Muffler Mystery 

On Apr 10, 5:23 pm, Virtualoso wrote:
> In article , Rob
>
>
>
> Kleinschmidt wrote:
> > On Apr 9, 8:16 pm, SaltineDawg wrote:
> > > The muffler looks right. That inside inset piece
> > > appears to be properly manufactured and completely integrated with the
> > > muffler... not just a gasket or whatever.
>
> > > It just doesn't fit the header tube.
>
> > If you don't think it's a pushed in metal gasket, then you
> > need to consult a parts diagram.
>
> > The diagram at this site is for a different model airhead,
> > but shows the kind of parts I'm talking about:
>
> >http://www.xmission.com/~wendell/GS/node48.html
>
> > The metal parts # 7, 8 and 10 are shown as "gasket". I think
> > what you're looking is a similar metal gasket pushed all the
> > way into the muffler.
>
> > If it's not a gasket and it really is integral, then you're apparantly
> > trying to put mismatched parts together and you need to
> > consult with a parts CD and/or parts guy to figure out the
> > right parts.
>
> > A good parts diagram will tell you what parts you
> > ought to be working with and offer some clues about how
> > the stuff fits together.
>
> > I wish you the best of luck but don't have anything more
> > to suggest.
>
> Thanks for all your attention, info and help.
>
> The only other thing I can think of here is that, at some point, the
> entire header pipe assembly had been changed, using one from some other
> model/year with a slightly different diameter.
>
> All parts involved *look* correct, as is. But they're just not fitting
> together right with this new muffler, which *is* the correct part for
> this year/model.

You're probably right. Looking at the parts diagram, there
are no gasket fittings shown, so that may mean a wrong
diameter pipe.

http://www.ascycles.com/Illustrated_catalog/R80_slash7(76-84)/catalog_frameset.html

Your next step would probably be to measure the diameters
of both the pipe and muffler, then figure it out from there.

Plastic calipers cost a couple of bucks at the hardware
store and do most jobs fine. A nicer electronic set might
run $30 on eBay. Figure out what's supposed to be on
the bike, then go from there.

If you didn't care about the pipes you could probably make
them work and look ugly by chopping the ends and welding
or brazing on a set of sleeves that fit the mufflers. Plan B
would be sell something on eBay and buy parts that matched.

Find out the standard specs and work towards them, selling
off or modifying the non-standard parts.
 >> Stay informed about: Airhead Muffler Mystery 

In article , Rob
Kleinschmidt wrote:

> On Apr 9, 8:16 pm, SaltineDawg wrote:
> > The muffler looks right. That inside inset piece
> > appears to be properly manufactured and completely integrated with the
> > muffler... not just a gasket or whatever.
> >
> > It just doesn't fit the header tube.
>
>
> If you don't think it's a pushed in metal gasket, then you
> need to consult a parts diagram.
>
> ... I think
> what you're looking is a similar metal gasket pushed all the
> way into the muffler.

You were right! It looked so well fit and integrated into the thing, it
had me fooled. But your certainty had me go mess with it and it turns
out to be a special made/pressure-fitted reducer shim which I could
remove.

Got the new muffler installed just fine now. Thanks!
 >> Stay informed about: Airhead Muffler Mystery 

On Apr 10, 6:29 pm, SaltineDawg wrote:
> In article , Rob
>
> Kleinschmidt wrote:

> > ... I think
> > what you're looking is a similar metal gasket pushed all the
> > way into the muffler.
>
> You were right! It looked so well fit and integrated into the thing, it
> had me fooled. But your certainty had me go mess with it and it turns
> out to be a special made/pressure-fitted reducer shim which I could
> remove.
>
> Got the new muffler installed just fine now. Thanks!

Damn I'm impressed with myself !!!

Now if you could just help me figure out how
to get myself back on the road....

Maybe another week or two.
 >> Stay informed about: Airhead Muffler Mystery 

In article , Rob
Kleinschmidt wrote:

> On Apr 10, 6:29 pm, SaltineDawg wrote:
> > In article , Rob
> >
> > Kleinschmidt wrote:
>
> > > ... I think
> > > what you're looking is a similar metal gasket pushed all the
> > > way into the muffler.
> >
> > You were right! It looked so well fit and integrated into the thing, it
> > had me fooled. But your certainty had me go mess with it and it turns
> > out to be a special made/pressure-fitted reducer shim which I could
> > remove.
> >
> > Got the new muffler installed just fine now. Thanks!
>
> Damn I'm impressed with myself !!!
>
> Now if you could just help me figure out how
> to get myself back on the road....
>
> Maybe another week or two.

I'm in your debt! What do you need to get back on the road?
 >> Stay informed about: Airhead Muffler Mystery 

SaltineDawg wrote:
> In article , Rob
> Kleinschmidt wrote:
>
>> On Apr 10, 6:29 pm, SaltineDawg wrote:
>>> In article , Rob
>>>
>>> Kleinschmidt wrote:
>>>> ... I think
>>>> what you're looking is a similar metal gasket pushed all the
>>>> way into the muffler.
>>> You were right! It looked so well fit and integrated into the thing, it
>>> had me fooled. But your certainty had me go mess with it and it turns
>>> out to be a special made/pressure-fitted reducer shim which I could
>>> remove.
>>>
>>> Got the new muffler installed just fine now. Thanks!
>> Damn I'm impressed with myself !!!
>>
>> Now if you could just help me figure out how
>> to get myself back on the road....
>>
>> Maybe another week or two.
>
> I'm in your debt! What do you need to get back on the road?

An intact skeleton...

--
Barb
Chaplain, ARSCC (wdne)

"Keep fighting for freedom and justice, beloveds, but don't forget to
have fun doin' it. Lord, let your laughter ring forth. Be outrageous,
ridicule the fraidy-cats, rejoice in all the oddities that freedom can
produce."

--Molly Ivins
 >> Stay informed about: Airhead Muffler Mystery 

In article , barbz
wrote:

> SaltineDawg wrote:
> > In article , Rob
> > Kleinschmidt wrote:
> >
> >> On Apr 10, 6:29 pm, SaltineDawg wrote:
> >>> In article , Rob
> >>>
> >>> Kleinschmidt wrote:
> >>>> ... I think
> >>>> what you're looking is a similar metal gasket pushed all the
> >>>> way into the muffler.
> >>> You were right! It looked so well fit and integrated into the thing, it
> >>> had me fooled. But your certainty had me go mess with it and it turns
> >>> out to be a special made/pressure-fitted reducer shim which I could
> >>> remove.
> >>>
> >>> Got the new muffler installed just fine now. Thanks!
> >> Damn I'm impressed with myself !!!
> >>
> >> Now if you could just help me figure out how
> >> to get myself back on the road....
> >>
> >> Maybe another week or two.
> >
> > I'm in your debt! What do you need to get back on the road?
>
> An intact skeleton...

Oh. Good idea.
 >> Stay informed about: Airhead Muffler Mystery 

On Apr 11, 3:13 pm, SaltineDawg wrote:
> In article , Rob
>
>
>
> Kleinschmidt wrote:
> > On Apr 10, 6:29 pm, SaltineDawg wrote:
> > > In article , Rob
>
> > > Kleinschmidt wrote:
>
> > > > ... I think
> > > > what you're looking is a similar metal gasket pushed all the
> > > > way into the muffler.
>
> > > You were right! It looked so well fit and integrated into the thing, it
> > > had me fooled. But your certainty had me go mess with it and it turns
> > > out to be a special made/pressure-fitted reducer shim which I could
> > > remove.
>
> > > Got the new muffler installed just fine now. Thanks!
>
> > Damn I'm impressed with myself !!!
>
> > Now if you could just help me figure out how
> > to get myself back on the road....
>
> > Maybe another week or two.
>
> I'm in your debt! What do you need to get back on the road?

I figure the most important thing I need is a couple of those
round tuits. The biggest reason the bike's still apart is
that I haven't been able to get a round tuit. If you got
any of them kicking around, please send me some.

The plan now is to run the engine parts over to my guy
in the south bay for a valve job and an inspection of the
ebay pistons I bought.

Long term, I'm in the market for a good set of Nikasil barrels
and 8.2:1 or better pistons. The barrels I've got have 137,000
miles on them and are starting to show some wear, so the
recommendation was for both new barrels and pistons.

The pistons I'm putting in cost $100, so I'm not too worried
about how long they last, so long as they get back on the
road while I shop for better. Leads on engines, top end
or jugs and slugs much appreciated. email to rkleinsc at
veritas.com.
 >> Stay informed about: Airhead Muffler Mystery 

In article , Rob
Kleinschmidt wrote:

> On Apr 11, 3:13 pm, SaltineDawg wrote:
> > In article , Rob
> >
> >
> >
> > Kleinschmidt wrote:
> > > On Apr 10, 6:29 pm, SaltineDawg wrote:
> > > > In article , Rob
> >
> > > > Kleinschmidt wrote:
> >
> > > > > ... I think
> > > > > what you're looking is a similar metal gasket pushed all the
> > > > > way into the muffler.
> >
> > > > You were right! It looked so well fit and integrated into the thing, it
> > > > had me fooled. But your certainty had me go mess with it and it turns
> > > > out to be a special made/pressure-fitted reducer shim which I could
> > > > remove.
> >
> > > > Got the new muffler installed just fine now. Thanks!
> >
> > > Damn I'm impressed with myself !!!
> >
> > > Now if you could just help me figure out how
> > > to get myself back on the road....
> >
> > > Maybe another week or two.
> >
> > I'm in your debt! What do you need to get back on the road?
>
> I figure the most important thing I need is a couple of those
> round tuits. The biggest reason the bike's still apart is
> that I haven't been able to get a round tuit. If you got
> any of them kicking around, please send me some.
>
> The plan now is to run the engine parts over to my guy
> in the south bay for a valve job and an inspection of the
> ebay pistons I bought.
>
> Long term, I'm in the market for a good set of Nikasil barrels
> and 8.2:1 or better pistons. The barrels I've got have 137,000
> miles on them and are starting to show some wear, so the
> recommendation was for both new barrels and pistons.
>
> The pistons I'm putting in cost $100, so I'm not too worried
> about how long they last, so long as they get back on the
> road while I shop for better. Leads on engines, top end
> or jugs and slugs much appreciated. email to rkleinsc at
> veritas.com.

What's your ride?
 >> Stay informed about: Airhead Muffler Mystery 

On Apr 12, 12:31 pm, Virtualoso wrote:
> In article , Rob
>
>
>
> Kleinschmidt wrote:
> > On Apr 11, 3:13 pm, SaltineDawg wrote:
> > > In article , Rob
>
> > > Kleinschmidt wrote:
> > > > On Apr 10, 6:29 pm, SaltineDawg wrote:
> > > > > In article , Rob
>
> > > > > Kleinschmidt wrote:
>
> > > > > > ... I think
> > > > > > what you're looking is a similar metal gasket pushed all the
> > > > > > way into the muffler.
>
> > > > > You were right! It looked so well fit and integrated into the thing, it
> > > > > had me fooled. But your certainty had me go mess with it and it turns
> > > > > out to be a special made/pressure-fitted reducer shim which I could
> > > > > remove.
>
> > > > > Got the new muffler installed just fine now. Thanks!
>
> > > > Damn I'm impressed with myself !!!
>
> > > > Now if you could just help me figure out how
> > > > to get myself back on the road....
>
> > > > Maybe another week or two.
>
> > > I'm in your debt! What do you need to get back on the road?
>
> > I figure the most important thing I need is a couple of those
> > round tuits. The biggest reason the bike's still apart is
> > that I haven't been able to get a round tuit. If you got
> > any of them kicking around, please send me some.
>
> > The plan now is to run the engine parts over to my guy
> > in the south bay for a valve job and an inspection of the
> > ebay pistons I bought.
>
> > Long term, I'm in the market for a good set of Nikasil barrels
> > and 8.2:1 or better pistons. The barrels I've got have 137,000
> > miles on them and are starting to show some wear, so the
> > recommendation was for both new barrels and pistons.
>
> > The pistons I'm putting in cost $100, so I'm not too worried
> > about how long they last, so long as they get back on the
> > road while I shop for better. Leads on engines, top end
> > or jugs and slugs much appreciated. email to rkleinsc at
> > veritas.com.
>
> What's your ride?

'88 BMW R100 GS.
 >> Stay informed about: Airhead Muffler Mystery