Exhaust Collector Repair

[uncledj]

For anyone who followed the thread, my 87 was making some crazy exhaust noise that caused me to remove and inspect the collector, the mufflers and the pipes several times.

The issue was resolved when I replaced a seemingly healthy collector.

I took the problem collector and cut it apart to see what was inside and what caused the problem.

Lemme tell ya. A healthy collector would be very tough to get apart without destroying it.

Using a die grinder with a cutoff wheel, I first cut along the perimeter of the bottom side hoping to peel away the skin with no luck. I was trying not to destroy it in the process, so I flipped it over and cut around the perimeter of the top, and although I had to cut through some of the perforated interior screen, I was able to get it apart mostly intact.

This was only possible because of what ended up being the problem, which was that the two welds that hold the bottom panel to the one baffle on the inside were broken. This must have been causing the loud sound and the rattle that I had.

I ended up re-welding the perforated screen anywhere that it had been pulled out during dis assembly. I then drilled 4 holes in the bottom panel where it contacted the baffle so that I could weld the baffle back on once I put it back together. I then welded the bottom panel that I'd cut back in place, then put the top back on, held it in place with a C clamp and welded it back on. I then flipped it over and welded the baffle to the bottom panel through the holes I drilled earlier.

I think the takeaway is that if you are getting these crazy sounds, it'd be worth it to run 3 sheet metal screws through the bottom panel into the baffle, in line with the 2 existing spot welds, one in the middle, and one forward of the front weld and aft of the rear weld. If that cures the problem, you at least know what the problem is, and can opt to leave the screws in and see how long it lasts, or pull the collector, drill a few holes like I did and weld the baffle back to the bottom panel without taking the thing apart.

In any case, I've welded mine and would be comfortable putting back on the bike, expecting no further issues.

If anyone else has this problem and can get their collector to me, I'd be happy to weld the baffle back in for them. Should be pretty easy now that I know what to do.