Suzuki gsx750e 1981

[hampshiregsx]

Hi all,
I tried searching but came up blank.
I have a 1981 Suzuki GSX750E.When acquired it had an aftermarket 4into 1 exhaust fitted.
I have since obtained an original stock 4into 2 exhaust in good condition.
As it comes in three sections and they have be fitted together on the bike,is there an procedure to follow to fit the exhaust?
I tried fitting the two pipes to cyclinders 1 and 4 and then the centre section to cyclinders 2 and 3 but could not find a way to fit 1 and 4 to the collector box.under the bike.
Any suggestions most welcome
Thanks
John

 

[Rich82GS750TZ]

It's a wrestling match for sure. I loosely assemble the pieces and with the bike on center stand, position the whole exhaust system on a floor jack under the bike. A 12" x 12" or so, 1/2" or so thick piece of scrap plywood panel between jack and collector help spread the weight/balance. Another pair of hands definitely helps, especially to keep the (4) 1/2 moon steel pieces in position while you get 2 & 3 lined up. I have been successful at holding these fiddly bits in place with thin gauge binding wire and cutting that off once all 4 header pipes are most of the way into their ports. I should have taken a video the last time I did it. It gets easier after about the 3rd or 4th time. Thankfully, don't have to do it very often. Hope this helps.

 

[hampshiregsx]

Thanks Rich,
That sounds like a good method.I will have another attempt tomorrow.I was thinking of using super glue to hold the half moon pieces in place during assembly.I would have thought the glue will let go during tighting up the retaining bolts ?

 

[Rich82GS750TZ]

If you use an adhesive I'd think it would burn and stink, and make a mess on startup. Personally, I would not. When putting the header bolts back in, I like to use a bit of anti-seize on the threads. Re-check torque on these from time to time.

 

[rphillips]

I use a round of masking tape to hold those half moon pieces, will just burn away quickly... Also I replace the exhaust "bolts" with the equal size "studs". When installing exhaust those collars will just hang on them then install nut, don't need to try to hold them up while installing bolt & not get bolt cross-threaded. Stock exhaust is a little aggravating, but you'll get there.

 

[hampshiregsx]

Thanks to the advice I have installed the Stock exhaust now It took a bit of fettling.I used elastic bands to hold the half moon pieces in place and then cut the bands with a knife before fully inserting the header pipes.
Thanks again

 

[Rich82GS750TZ]

Thanks to the advice I have installed the Stock exhaust now It took a bit of fettling.I used elastic bands to hold the half moon pieces in place and then cut the bands with a knife before fully inserting the header pipes.
Thanks again

That's even easier than my idea with the wire. Will use rubber bands next time. Brilliant.