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    Header flange clamps bent

    This Kerker has bent clamps at the header flanges. Looks like possible overtightening sometime in it's history. Should I try to straighten these during the refurbishment I'm doing? Anyone dealt with this before? Thanks

    IMG_2743.jpg
    Last edited by dweller; 06-14-2019, 11:56 PM.
    1982 GS1100EZ, second owner, 11,000 miles
    2000 XR650R, plated

    #2
    I have this on my SuperTrapp. I just can't figure a way to bend them back.

    And what will stop them bending again if I did.
    Richard
    sigpic
    GS1150 EF bought Jun 2015
    GS1150 ES bought Mar 2014: ES Makeover Thread AND blog: Go to the Blog
    GS1100 G (2) bought Aug 2013: Road Runner Project Thread AND blog: Go to the Blog
    GS1100 G (1) Dad bought new 1985 (in rebuild) see: Dad's GS1100 G Rebuild AND blog: Go to the Blog
    Previously owned: Suzuki GS750 EF (Canada), Suzuki GS750 (UK)(Avatar circa 1977), Yamaha XT500, Suzuki T500, Honda XL125, Garelli 50
    Join the United Kingdom (UK) Suzuki GS Facebook Group here

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      #3
      With these pipes you have the option of heating up the flanges and tapping them back to shape. (Assuming you have access to a torch and gas)
      The big guy up there rides a Suzuki (this I know)
      1981 gs850gx

      1999 RF900
      past bikes. RF900
      TL1000s
      Hayabusa
      gsx 750f x2
      197cc Francis Barnett
      various British nails

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        #4
        common as far as i can tell, and not really a problem, at least with my yosh.
        1983 GS 1100 ESD

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          #5
          Originally posted by dweller View Post
          This Kerker has bent clamps at the header flanges. Looks like possible overtightening sometime in it's history. Should I try to straighten these during the refurbishment I'm doing? Anyone dealt with this before? Thanks

          [ATTACH=CONFIG]58257[/ATTACH]
          Those don't look to bad. I made a tool for straightening the flanges on my Yosh, as they were REALLY bent. I'll see if I can find it and take some photos.
          The Three Horsemen
          '85 GS1150ES (Current Income Eater)
          '83 GS1100ES
          ‘77 XLCR

          "Never ride faster than you can see. Besides, it's all in the reflexes."
          Porkchop Express

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            #6
            Originally posted by Greg B View Post
            Those don't look to bad. I made a tool for straightening the flanges on my Yosh, as they were REALLY bent. I'll see if I can find it and take some photos.

            Okay thanks!
            1982 GS1100EZ, second owner, 11,000 miles
            2000 XR650R, plated

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              #7
              Here was my solution. Made a special tool out of some thick wall 1.5" ID aluminum tubing. Cut out one side and ground so that it would barely slip over the header tube. Found a truck axle nut socket in the tool box that fit over the flange and then clamped the whole thing in a big vice. Hydraulic press would work too. Worked great and pushed the clamps back almost perferctly straight.

              IMG_2751.jpg
              1982 GS1100EZ, second owner, 11,000 miles
              2000 XR650R, plated

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                #8
                IMG_2752.jpg

                Here showing the socket I used...
                1982 GS1100EZ, second owner, 11,000 miles
                2000 XR650R, plated

                Comment


                  #9


                  Something like this might help prevent them from warping again. Sort of a sleeve/reinforcement around the bolts between the flange and head.
                  1983 GS 1100 Guided Laser
                  1983 GS 1100 G
                  2000 Suzuki Intruder 1500, "Piggy Sue"
                  2000 GSF 1200 Bandit (totaled in deer strike)
                  1986 Suzuki Cavalcade GV 1400 LX (SOLD)

                  I find working on my motorcycle mildly therapeutic when I'm not cursing.

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