Topic: Header pipe...size at the muffler end

[gregwaits]

I have a 4-1 for my cb500 (73), and I am having a helluva time trying to locate a muffler for it. The outlet measures around 2" across, yet all of the mufflers that are offered are measured smaller at the connection end.

I have checked with Dennis Kirk, JC Whitney, Oldbike barn, etc etc. This is becoming very frustrating. Apparently I am stuck with an after market 4-1 with oversized pipes.

Any advice? I hate to have to get a muffler shop to make a custom setup for me. That will really blow the budget!

[dusterdude]

greg,what sizes are the mufflers you are finding?

[gregwaits]

They measure anywhere up to around 1 5/8", and are designed to slip over the header pipe. Maybe I am measuring it wrong, but it seems to big to have even that size pipe slip over it.

[eldar]

Well there are a couple things you can do.  Measure the O.D. of your header to make sure you have the right size. The find a muffler you want and get the I.D. size. Then  go to a exhaust shop and have them take a 3 - 4 inch piece of scrap exhaust pipe and have them make one end have an I.D. of 2 inches or maybe slightly larger and this end will fit over your header, and the other end O.D. just slightly smaller than the I.D. of the muffler.   Fit the piece to the muffler and tighten it. Then put the other end over the header and then you can either seal it by gas welding or other low heat weld OR you can get a metal repair epoxy and seal it with that. You can polish up the connecting piece and it will blend in better.  Not pretty but then if you were really worried about pretty, you would drop $300 for a new 4-1

The other option is to do the same basic thing EXCEPT make the end that goes to the header fit inside as well and then you can butt the header and muffler together and weld it.

I had to do the first way and it is not super pretty but then my whole bike needs paint!

[dusterdude]

eldar,you stole my idea,thats what i would do.

[eldar]

thats what I did do. It works pretty good.

[FunJimmy]

You could search ebay for Kerker  mufflers. I found one with an aluminum body and 2" I.D.
Have seen others listed too.