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Holes in my Mufflers..Recomentations on what to replace with

Another solution. Collar welded to the double walled header pipes on my 83XS650
thumbnail_image0.jpg
 
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Final fitting..........slip the small end of the adapter, over the inner pipe, under the outer pipe, Tight fit. Slip the muffler over the adapter and but up to the chrome header and fasten This should make a good seal with no leaks
muffler2.jpg
 
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Header pipe from a XS650 Special, with the muffler cut off. these models had a full header/muffler, one system, from the factory

inner.jpg
 
Under the exhaust, to the far left, showing where the heat shield bolts on around the area where the header and muffler meets i think.
thumbnail_image8e.jpg
 
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Series of pics showing the exhaust and solutions to cutting the muffler off the double walled headers

Semantic of the whole exhaust
MjEzMDcxMQ-a261b573.jpg
 
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@ metalfab Yes, you bring up all the points that can be problematic in this situation. No, on the bone yards, these models are thin on the ground as is and i don't even know if they were factory sold into NZ. This bike was imported by the PO about 3 or so years ago from Canada.



Yes i am aware the headers are double walled and cutting the factory muffler off the header the inner pipe has to be made to connect a slip on Muffler. Then made to seal so the exhaust fumes won't go back between the inner and out pipes on the header.

there are 2 ways to do this. Getting the right reducer/adapter that slips over the inner pipe from the header and expands so the slip on muffler goes over the large end of the reducer/Adapter. These come in different sizes.

Shows in sequence in Posts #25,#24,#23

The second way is to weld the inner and outer pipes together and weld a collar on so a slip-on muffler can be used. Post #22, #21

Making it suit, (as in looking close to original or just good), is an issue as the GS650E exhaust had a small heat shied bolted to the header where it expanded out to the Muffler. Where to cut is also and issue as i haven't had any experience with these.

If someone has done this before i would be very grateful to hear how it was done and some measurements on where the best place is to cut
 
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