Magnum Exhaust But Probably Generic By ellpee (Read 730 times)

[ellpee]

Since I got my Magnum (12 months, around 1100 miles) I've had to mess with the exhaust system a couple times, because there's a piece of woven metal "pipe" between the exhaust header and the muffler. I'm sure it has to be there to handle the flexing and vibration, but it won't stay in place and give a reasonably tight exhaust seal. The deal is, the flex stuff fits into the header, no fastener or anything. At the other end it is welded to a solid piece of pipe that fits into the muffler, and there is a big, more or less typical exhaust clamp that you would think will hold that intermediate piece in the proper position. NOT! The big clamp is squeezing on a very solid steel tube at the front end of the muffler, and I don't care how much you tighten it, it isn't really holding anything in place.

So today, after it worked loose again, I looked, thought, and came up with this. The header is fixed in position, ain't gonna be movin'. Ditto for the muffler, two bolts, ain't gonna move. So I decided I'd add another standard hose clamp that would keep the flex&solid intermediate piece from slipping any further back into the muffler, and thereby coming loose from the header.

Not at all sure that comes across clearly in just words, so am attaching some pictures. Pictures didn't post in the expected order, but what they show is, #2, the original setup on my workbench, #1, #2 same with added clamp still on my workbench, #3 assembled on one side with added clamp in place. Will report back here after a few test drives and let everybody know if this worked out the way I hoped.

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[alleyoop]

The real problem is that the muffler most likely is connected to the frame and not the SWINGARM that the motor is mounted to. If it where then the piping and muffler would move with the motor and all be be peachy keen and you would not need any of the flex stuff.
Alleyoop

[ellpee]

Jun 9, 2014 14:00:57 GMT -6 alleyoop said:

The real problem is that the muffler most likely is connected to the frame and not the SWINGARM that the motor is mounted to. If it where then the piping and muffler would move with the motor and all be be peachy keen and you would not need any of the flex stuff.
Alleyoop

True dat. I assume that's why they engineered in that piece of flex. I put a few miles on it this afternoon and so far it seems okay, but time will tell. The really goofy part is that big ol' clamp on the front of the mufflers that has pretty much no effect. Because of that, over time the "hard pipe" part of the intermediate piece slips further and further into the muffler, and sooner or later the flex comes out of the header. Hoping that second clamp on the "hard pipe" will prevent that from happening. One more thing to check for tightness on a regular basis, though. I also find it goofy that the flex just fits into the header, but with nothing to provide an actual seal. Over time it gets black, as a certain amount of exhaust is gonna get by that half-assed connection.

[alleyoop]

What I would do is make a bracket and bolt the muffler to the Swingarm that the motor is mounted to then you can do whatever you want with the rest of the piping to the muffler no flex crap on it.
Alleyoop

[ellpee]

WA-A-AY above my paygrade. I might, though, if my current "fix" doesn't work out, try some "hard-sided" flex pipe instead of that woven, steel-mesh junk. You know, the kind that looks like a universal radiator hose, only metal. Surely if I go that route I could find a way to get a good seal at the fron (header) end.

[alleyoop]

Well I spent money to save money and work. I had to replace mine 2 times at $106.00 a shot. I said SELF do you want to keep buying this crap every year or get it fixed right. SELF said get it fixed right and VIOLA 3 1/2 years later not a dime spent on any part of the exhaust or muffler and it still looks new.
Alleyoop

[ellpee]

I stopped reading at that "make a bracket" part. My son-in-law might be able to do that (though he'd have to do it twice, this is a trike, after all), but it goes way, way beyond my skillset.

[ellpee]

UPDATE: have been on about three runs so far, lots of bumpy roads, and my "cure" for the exhaust problem seems to be doing the job. So simple.