Airhead Muffler Mystery

Discussion in 'Bay Area Bikers' started by SaltineDawg, Apr 9, 2007.

  1. SaltineDawg

    SaltineDawg Guest

    I bought a new muffler off eBay, as the former one broke off while

    I undid the clamp on the header pipe that was holding the broken end of
    the muffler and had to chisel off the remainder. Seemed to go okay.

    But now the new muffler won't slide on there far enough. Inside the
    muffler outer housing is another, slightly smaller diameter tube, inset
    from the end of the muffler housing about 1/2"... and too small to
    slide up over the header pipe.

    SaltineDawg, Apr 9, 2007
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  2. Some mufflers use a soft metal gasket between a pipe
    and collector box or muffler. My bet would be that you've
    got some kind of shim or gasket that's been pushed
    partway into the muffler.

    If you've got a local dealership, ask the parts guy
    nicely if he can show you the diagram for the muffler
    assembly. My bet would be there's a stock gasket.

    It's also possible that somebody kluged this together
    trying to fit the muffler onto a pipe that was smaller
    than stock.

    In any case, I'd see if I could use some kind of hook
    thingy to fish the sucker out. I doubt it's fastened in.
    Auto parts stores can sell you a cheap set of hooks
    and picks that would likely do the job for you.
    Rob Kleinschmidt, Apr 9, 2007
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  3. SaltineDawg

    SaltineDawg Guest

    I don't think so. The muffler looks right. That inside inset piece
    appears to be properly manufactured and completely integrated with the
    muffler... not just a gasket or whatever.

    It just doesn't fit the header tube.
    SaltineDawg, Apr 10, 2007

  4. If you don't think it's a pushed in metal gasket, then you
    need to consult a parts diagram.

    The diagram at this site is for a different model airhead,
    but shows the kind of parts I'm talking about:

    The metal parts # 7, 8 and 10 are shown as "gasket". I think
    what you're looking is a similar metal gasket pushed all the
    way into the muffler.

    If it's not a gasket and it really is integral, then you're apparantly
    trying to put mismatched parts together and you need to
    consult with a parts CD and/or parts guy to figure out the
    right parts.

    A good parts diagram will tell you what parts you
    ought to be working with and offer some clues about how
    the stuff fits together.

    I wish you the best of luck but don't have anything more
    to suggest.
    Rob Kleinschmidt, Apr 10, 2007
  5. SaltineDawg

    Virtualoso Guest

    Thanks for all your attention, info and help.

    The only other thing I can think of here is that, at some point, the
    entire header pipe assembly had been changed, using one from some other
    model/year with a slightly different diameter.

    All parts involved *look* correct, as is. But they're just not fitting
    together right with this new muffler, which *is* the correct part for
    this year/model.
    Virtualoso, Apr 11, 2007
  6. You're probably right. Looking at the parts diagram, there
    are no gasket fittings shown, so that may mean a wrong
    diameter pipe.

    Your next step would probably be to measure the diameters
    of both the pipe and muffler, then figure it out from there.

    Plastic calipers cost a couple of bucks at the hardware
    store and do most jobs fine. A nicer electronic set might
    run $30 on eBay. Figure out what's supposed to be on
    the bike, then go from there.

    If you didn't care about the pipes you could probably make
    them work and look ugly by chopping the ends and welding
    or brazing on a set of sleeves that fit the mufflers. Plan B
    would be sell something on eBay and buy parts that matched.

    Find out the standard specs and work towards them, selling
    off or modifying the non-standard parts.
    Rob Kleinschmidt, Apr 11, 2007
  7. SaltineDawg

    SaltineDawg Guest

    You were right! It looked so well fit and integrated into the thing, it
    had me fooled. But your certainty had me go mess with it and it turns
    out to be a special made/pressure-fitted reducer shim which I could

    Got the new muffler installed just fine now. Thanks!
    SaltineDawg, Apr 11, 2007
  8. Damn I'm impressed with myself !!! :)

    Now if you could just help me figure out how
    to get myself back on the road....

    Maybe another week or two.
    Rob Kleinschmidt, Apr 11, 2007
  9. SaltineDawg

    SaltineDawg Guest

    I'm in your debt! What do you need to get back on the road?
    SaltineDawg, Apr 11, 2007
  10. SaltineDawg

    barbz Guest

    An intact skeleton...

    Chaplain, ARSCC (wdne)

    "Keep fighting for freedom and justice, beloveds, but don't forget to
    have fun doin' it. Lord, let your laughter ring forth. Be outrageous,
    ridicule the fraidy-cats, rejoice in all the oddities that freedom can

    --Molly Ivins
    barbz, Apr 12, 2007
  11. SaltineDawg

    SaltineDawg Guest

    Oh. Good idea.
    SaltineDawg, Apr 12, 2007
    Rob Kleinschmidt, Apr 12, 2007
  13. SaltineDawg

    Virtualoso Guest

    Virtualoso, Apr 12, 2007
    Rob Kleinschmidt, Apr 13, 2007
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