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post #1 of 5 (permalink) Old 4-20-2017, 4:30 PM Thread Starter
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Stock Exhaust Too Short?

I low-sided my 2001 going into a turn and ended up denting the left-side exhaust pipe right under the engine. I ordered a stock replacement off eBay, and the posting described it as coming off a 2002.

Fitted it up and everything was going fine, until I tried putting the muffler on (left side), and realized the hanger bracket doesn't line up with the mount/foot peg. It's short by about an inch, meaning if I push the muffler on all the way to the shoulder, then the hole in the muffler hanger is about an inch too far forward of the footpeg mount. If I back it off, so that the holes align, then the muffler isn't fully seated, and there's about an inch (maybe more) of pipe between the shoulder and the beginning of the muffler.

Any ideas what could cause the discrepancy?

Also, when I put the exhaust flanges/holders back on, they do not sit flush with the engine head, even when I tighten them down evenly. I can't remember if they originally sat flush, or not, and can't find a good picture online. The header flanges seem to be seated completely onto the exhaust port.
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post #2 of 5 (permalink) Old 4-20-2017, 7:12 PM
bpe
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If I'm understanding what you are saying, then everything connecting to the engine should be flush. What if you took a picture of what you have, then everyone could tell you if it looks right. I have to do a major computer cleaning before I can put up more pictures, your picture would probably look better anyway. If you haven't changed the right side muffler, you should be able to use that as a reference.

2006 Ninja500R Purchased new July 2006, 0 miles. Miles as of January 2017 88652. It is a GO bike, not a SHOW bike.
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post #3 of 5 (permalink) Old 4-21-2017, 10:36 AM Thread Starter
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Thanks for the reply. I've got some photos posted, but can't post yet... I'll post a couple more times and try again.

After going over it again last night, it looks like the "new" LH exhaust header is bent out of shape. There's a good 1.25" between it and the frame, whereas on the RH side, there's hardly any gap (You can see it in the pictures). Also the crossover pipe looks to be bent out of square (also in the pictures), which would move it farther forward. Took a deadblow hammer to it, but don't think I moved it much.

As it sits right now, I can get the can on about halfway. I figure that may be enough to seal, or if not I can make a little extension bracket out of some flat bar.

Or really, this may be the excuse I need to get some Delkevic stubbies. The RH can also has a giant crack in it.
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post #4 of 5 (permalink) Old 4-21-2017, 11:37 AM Thread Starter
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post #5 of 5 (permalink) Old 4-21-2017, 1:09 PM
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looks like you just need to rebend the pipes a lil better. use leverage and a vise to make it easier.

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