Is this typical ..

So,

I took the rear master cylinder off this 86 GPz550 today and what a
mess.

Loads of corrosion (ally and steel) brake lever partially seized in
it's sub frame, retaining circlips (pingfuckits) rusted / gunged in
and rusting away.

However, I'm not really worried about all that, the bit that bothered
me the most is when I took the bolt out to release the rear of the
exhaust (so I could get the footpeg carrier / brake stuff off easily)
it sprung down probably ~20mm. Not dropped down as in under it's own
weight but pulled down as in had been pulled up ~20mm to make it fit?

FWIW it's a black 4 into 1 Neta system. Is this just how well (or not)
this aftermarket stuff generally fits or does it indicate something
else, like it wasn't fitted to the engine properly in the first place
(is there any 'adjustment' in the engine end or is it just clamped up
square)?

If the panel agrees it's not 'good' as-is, I'd be tempted to cut the
mounting plate across and weld or bolt a lengthening plate to it, so
at least it' sits on it's mount with no tension (there isn't enough
meat above the existing hole to slot or redrill it higher).

All the best ..

T i m

p.s. It looks like none of this has been touched for all of it's 22
years. :-(

 

Motad's aren't the greatest of fits but should be "ok" and not too much
force should be needed. It sounds like it was clamped up at the cylinder
head with the weight of the silencer pulling it down, before the rear
mount was offered up.

Slacken the clamps at the cylinder head/header pipe (I've forgotten what
to call them again), then raise the silencer mounting bracket into
position then retighten the exhaust clamps.

....or if they look like they'll shear off just use a jack to get the
exhaust back in position and don't worry about it.

I've recently had a bit of practice removing and replacing exhausts on
four cylinder Kawasakis and it's not my idea of fun as a solo activity.

 

When I've finished with stuff they usually fit with no force needed.
;-)

Ah, that was my question Sweller. It looks like this bike uses a
pretty standard clamp / gasket setup (just like my CB Two Fifty and

Wouldn't they just pull back into the same position if I didn't use
new gaskets?

I won't worry (as in worry) but I would bother with it. Like I
mentioned elsewhere, I would probably just cut the mounting tang
across and weld / bolt in an extra section to allow the holes to line
up easily (as they should). ;-)

I bet (like putting scaffolding up on yer own).

Feeling underneath this exhaust at the joint it feels like just one of
the (4) down pipes is clamped to the silencer section. I'll give the
bolt a squirt of Plus-Gas and I should be able to pull the silencer
off the pipes to work on the bracket. Or maybe I'll get 4 new exhaust
gaskets and just re-fit the assembly and see where it ends up afresh?

All the best ..

T i m

 

What's probably happened is the numpty who fitted it didn't quite get it
right and you'll find that if you were to fit a new one where all the
pipes slide nicely into the collector you could align it properly and
there might even be a proper bracket. All that's by the way of course,
if what you have to work with is a pile of tissue-thin rust. I'd
lengthen the bracket to suit and avoid straining the joints.
--
Dave
GS850x2 XS650 SE6a

"It's a moron working with power tools.
How much more suspenseful can you get?"
- House

 

You may well be right Dave. Any idea what the general rep on these
systems is?

I don't know that these won't slide out / in yet. It looks like they
might?

Erm, there is a proper bracket just with the current setup the hole
(or system) is 20mm out.

Well I don't know what's inside / under the paint of course but atm
they look like 4 neat black pipes?

Yeah, I think I will Dave. If I cut it across and re-joined it with a
bolted plate I could even use slotted holes and make it adjustable.
;-)

All the best ..

T i m

 

It's a shite old bike, just bodge it. It's not as if you're going to
enter it into a concours event is it ..

P.

 

Well, you (generally) get's what you pays for and I assume it wasn't
the most expensive system available.

Oh, ok. <waits for nice Motad rep>

All the best ..

T i m.

 

At the moment maybe. When I'm finished with it I hope it's a tidy old
bike. ;-)

Nah, I just can't work that way.

No, but if it's a wreck and I haven't touched a particular bit of it I
can be content it wasn't any of doing. If I do touch a bit it has my
signature on it and I like to think that whatever I do I do to the
best of my ability (and that normally only takes a few more moments
than doing a shabby job and generally lasts longer). I've rarely had
to re-fix anything I've ever fixed.

If a jobs worth doing it's worth doing well. ;-)

The bottom line is I don't want to be sliding down the road or pushing
it home simply because I bodged something I could have done properly.

All the best ..

T i m

 

Ah, the exuberance of youth. You will learn the art of SOB bodging
soon enough Daniel-San.

P.

 

There's no real excuse for bodging anything when you have the tools and
know how to do a proper job.

 

Laziness ? Quick cost/benefit analysis ? When you've no time or
materials ?

There's a difference between

1) bodging dangerously,
2) bodging as a quick or temporary fix, or
3) bodging to save yourself a shit load of cash against the cost of a
new part.

I do 2) and 3) occasionally, and avoid 1)

P.

 

I'm not sure that ever comes into it for me? If I'm not feeling in the
mood to do a job properly I generally won't do it at all.

Well, true but again probably never a bodge, more like how good
(rather than bad) a job I do. I would suggest in many people eyes even
my worst acceptable job would be 'pretty good' in most people eyes.

Then you don't do it.

We aren't really talking about emergency get_you_home jobs here as
even I will do what it takes to make that happen, we are talking of
those times where there is a choice and some choose not to do it to
the best of their abilities (and I'm not talking about perfection here
either, just a well thought out and implemented solution.

I have probably even done 1) now and again, to get me home etc. One
instance was in my Morris Minor Van when the nearside steering trunion
pulled out of it's thread (like they do). I jacked the assembly back
together then made a Spanish Windlass with some rope and a screwdriver
between the lower radius / torsion arm and the upper damper linkage,
then carefully drove home (and made it). ;-)

I may have done 3 but it depends on how you define the bodging. eg. If
I found the anti-dive on this GPz550 wasn't working and needed
blanking off the blanking plates (the bodge bit) would be very neat,
far neater than they would need to be to simply do the job.
Sufficiently neat for people to ask, "where did you buy them / get
them machined" etc. Would that make them work any better, no. Would
that take longer to do, yes. Could I do it any other way, even if it
was for someone else, no.

Years ago I was running some waste pipe behind our sink and I cut a
bit about 2mm short. I cursed a bit to myself, pulled it out and
started cutting another length. The Mrs asked what was wrong with the
fist bit and why didn't I leave it?

Her "Will it leak or anything?"
Me "Probably not"
Her "No one will see it will they?"
Me "No"
Her "Then why bother cutting another bit of pipe?"
Me "Because this bit isn't right.

All the best ..

T i m

 

If the Motad (I thought it was Motard for some reason) chap turns up
ask him about stainless steel ZXR 400 ones would you...

 

Ok, I'll try to remember. Any questions in particular?

All the best ..

T i m

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=250137224649

 

MOTAD MAN HERE!- lurking sounds underhand- I am just here to help

A few issues here

1. 250 RS- give me the fabrication number off the back of the silencer
and we can see how old it is- bad corrosion is rare but when this
happens it because the silencer is years old - and our fairly decent
chrome makes it look youngert than it is.
Decking out a 2-1 system is easier but we have sold this product for
20 years + without anyone actually contacting us about this. Your
surname isnt Corser or Rossi?

2. On fitting issues- contact us on 01922-714700 or you can get me on
my mobile 07702-876988. I believe Motad is the last volume
manufacturer actually making motorcycle silencers here in the UK-
central to this is you guys speaking direct to us.

Can we make our exhausts better?- yes we could and we are doing so as
much as increased costs allow- but the bottom line is that if you have
a bike worth £750- then the market price for an exhaust needs to be
perhaps 30% of this (£220) or it will not sell. We can make full
stainless steel (we do for many bikes) exhausts which will last
better- but how many are you goingto buy at £450?

Ian McDonald

 

The 250RS is long gone from my stable, but it is now wearing another
one of your exhausts.

http://www.flickr.com/photos/entwisi/2784823394/sizes/l/in/set-721576068
74622179/

I'm no Rossi or Corser, but I do like a bit of dangle-angle. I used the
250RS to do a 25 mile each way commute towards the end of its time with
me, and a fair bit of that was along twisty country roads with 90 deg
bends.

 

Those little one-piece collets that clamp the header pipes up on stuff
like GT750 Kawasakis, can't you make those from stainless steel as the
lifespan of your mild steel ones on year round commuters like GTs isn't
very long.

 

Well hello, and thanks very much for popping up! ;-)Re the Neta system on my (new to me) 85/6 Kawasaki GPz550 and it's
seeming poor fit ... I may have an update for you.

I just went out to take the details off it and on closer inspection
(and in better light) it seems the silencer is actually bolted to the
mounting bracket (it looked like it was welded on from the top) and
using slotted holes? This means there is the potential that:

1) it was never adjusted properly when it was first fitted, or has
eased since that time and I may be able to adjust out the poor fit
(bracket mounting hole is 20mm out (low) compared with the bike) using
the existing slots.

2) assuming I can undo the mounting nuts (to try 1 above) I can also
extend the slots to accommodate the current 'lay' of the system and
ensure it is not under any stress when re-fitted.

FYI, the system reads:

Motad. Made in the UK.
BSAU 193 T2
TYP NZ5
TPSI 2119
Fabn No 4455

I'll let you know how I get on. ;-)

All the best and thanks again for popping up Ian (not many Co's will).

T i m

 

You are right- we have been making the headrings in stainless steel
for about a year-( available from Walsall)

We also use stainless for all pipes- better corrosion resistance- and
we have not increased prices

As regards the ZXR400 pipes and collector- we dont do one, but we
could if there was some interest of perhaps 10 people.
One problem we have is the Chinese stuff now coming in- no R&D and
customer support means the Chinese (junk?) are really cheap- or seem
to be until they dont fit or work. The one thing they do is come to
the market at a very low price- which of course make the Motad look
expensive!. - but you are paying for a product that works properly and
also (here is the bottom line) if you have a problem/question/
suggestion with a Motad you can talk direct to the designer/welder or
whatever- and we will listen and react if you make a decent proposal

 

Wonderful, thanks. About three years ago I had to fabricate some for a
friend from a bit of Renault 21 exhaust pipe. I also had to make them
for the CB250RS IIRC.