Silencer/Pipe Tight Fit Solution?

[RonC]

I bought my 04 ec200 used with a FMF Fatty pipe(discontinued for the 200) on it and did the 2011 conversion. I bought a 2011 FMF silencer(Q stealth) to fit the new alloy subframe silencer mounting bracket as the old one doesn't line up.

-The new silencer seems to line up with the subframe mounting, but the fit seems off by a millimeter or so It slips on only 1/4th or 1/3 of the way.
-The smallest automotive tailpipe expanders (1 1/8") are literally the same diameter and are millimeters too big to slide in and do the job.
-Muffler shops don't have equipment for 1 1/8th tube/pipe expansion.
-The old silencer looks like a Turbincore or Powercore.

It really looks like the silencer needs to be bigger by 1-2 millimeters or the pipe needs to be taken down slightly. I've already tried dremeling slightly but I'm cautious of taking off material. Any suggestions on parts or methods? Thanks for any help.

 

[Anders]

I bought my 04 ec200 used with a FMF Fatty pipe(discontinued for the 200) on it and did the 2011 conversion. I bought a 2011 FMF silencer(Q stealth) to fit the new alloy subframe silencer mounting bracket as the old one doesn't line up.

-The new silencer seems to line up with the subframe mounting, but the fit seems off by a millimeter or so It slips on only 1/4th or 1/3 of the way.
-The smallest automotive tailpipe expanders (1 1/8") are literally the same diameter and are millimeters too big to slide in and do the job.
-Muffler shops don't have equipment for 1 1/8th tube/pipe expansion.
-The old silencer looks like a Turbincore or Powercore.

It really looks like the silencer needs to be bigger by 1-2 millimeters or the pipe needs to be taken down slightly. I've already tried dremeling slightly but I'm cautious of taking off material. Any suggestions on parts or methods? Thanks for any help.

I'm afraid this does not answer your question, but this is how I did it:

I have a 2006 200 with a 2005 FMF Gnarly, 2006 OEM silencer and 2011 transformation kit. I moved the silencer sideways to make it line up with the Gnarly and the new subframe.
I put the rear mounting point on the silencer on the opposite side of the subframe (the outside). Then I measured the distance at the front mounting point and made an aluminum part with some threaded holes to make everything fit together.

Has been like that for a couple of months, no problem so far.
I might take a photo and post it here if someone wants to see it.

 

[nknudsen]

If you have access to a tig or last resort mig welder, cut the slip fits off of both silencers and weld the other one on. Keep in mind the stealth takes up a lot of space and needs to fit perfect to avoid tire rub against it with a larger tire. Good luck with the project!

 

[RonC]

A photo of the bracket would be great. Thanks for the info on how you did your 2011 conversion.

Thanks for the welding idea. If expanding/reducing the pipe or silencer is not feasible, swapping that portion of the silencer is a good idea that I haven't thought of before.

FMF still makes a Gnarly pipe for my year of bike and I wonder if the 2011 Q Stealth(250/300 model) will fit on it without the fitment issues that the discontinued Fatty pipe has.

 

[desertgasser300]

Just finished this conversion on my wifes 97'. My old silencer fit just fine, it was maybe off by less than 1/4 in. And as you can see in the pic the lower mount had a space that I just used a 3/4 inch anti-vibration mount.

 

[nknudsen]

Just finished this conversion on my wifes 97'. My old silencer fit just fine, it was maybe off by less than 1/4 in. And as you can see in the pic the lower mount had a space that I just used a 1/2 inch anti-vibration mount.

You forgot to add the picture of the completed bike

 

[desertgasser300]

You forgot to add the picture of the completed bike

Not til the graphics come in. It looks a little "ratty" without them, but I did use all black for the plastic conversion. Soon as I get those graphics mounted I will post some pics.

 

[Anders]

A photo of the bracket would be great. Thanks for the info on how you did your 2011 conversion.

Here they are:

The silencer is somewhat more to the right than before. I doubt if the big Q-Stealth could be mounted like this without hitting the plastic.

Here you see the front mount aluminium adaptor.

The complete bike (incuding KYB conversion)

 

[RonC]

Thanks and BTW, where do you get your rear light/plate holder piece?

Thanks for the replies and photos of your guys' solutions. I ended up hammering something as a punch to barely enlarge the silencer end(and a torch to get the damn thing back out ). It worked beautifully as only 1-2mm was needed.

By the way, where do you guys get your cool minimal rear fender portion that includes the tail light and plate holder? My kit came with the giant monstrosity that extends well below the bottom of the license plate(as shown in the catalog photo side shot). I know there are pieces for Japanese bikes and KTMs, but it'd but nice to get something that mounts to the 2011 subframe instead of punching holes in existing plastic.

 

[nknudsen]

Thanks for the replies and photos of your guys' solutions. I ended up hammering something as a punch to barely enlarge the silencer end(and a torch to get the damn thing back out ). It worked beautifully as only 1-2mm was needed.

By the way, where do you guys get your cool minimal rear fender portion that includes the tail light and plate holder? My kit came with the giant monstrosity that extends well below the bottom of the license plate(as shown in the catalog photo side shot). I know there are pieces for Japanese bikes and KTMs, but it'd but nice to get something that mounts to the 2011 subframe instead of punching holes in existing plastic.

On mine, I just cut right along the indent line in the plastic of the monstrosity fender.

 

[desertgasser300]

On mine, I just cut right along the indent line in the plastic of the monstrosity fender.

What he said! If you have a heat gun and a sharp utility knife it will make short work of it. Ha get it short work???? Keep heating the area along the indent and soon it will become soft and the knife will flow right thru it.

 

[pscook]

Let me know if you are interested in selling that monstrosity. I am looking for a tail light/fender/plate mount for my 2011.

 

[RonC]

Thanks for the tips on cutting the whale tail. I was just thinking, "hmm.. that line is pretty damn conveniently placed.. almost like a perforation line."

Pscook: I may very well sell it since I need to get my bike plated soon. And we also live pretty damn close so I could drop it off on my way to Seattle. Are you going to the Everett AMA Endurocross stop on Oct 26th?

And can you recommend a place to do wiring? My digital gauge doesn't work, the light switch does nothing, and I need to wire the headlight/tail light plus turn signals, etc. My only lead is Cyclops Adventure Sport in Kent since they definitely have the experience from their lighting kits.

 

[pscook]

Thanks for the tips on cutting the whale tail. I was just thinking, "hmm.. that line is pretty damn conveniently placed.. almost like a perforation line."

Pscook: I may very well sell it since I need to get my bike plated soon. And we also live pretty damn close so I could drop it off on my way to Seattle. Are you going to the Everett AMA Endurocross stop on Oct 26th?

And can you recommend a place to do wiring? My digital gauge doesn't work, the light switch does nothing, and I need to wire the headlight/tail light plus turn signals, etc. My only lead is Cyclops Adventure Sport in Kent since they definitely have the experience from their lighting kits.

I would love to, but I am going to Rich Oliver's mystery school that weekend. I'm pretty sure that I will have friends attending who would pick it up for me. Bummed as I have made the last few EC events.I can't recommend anyone for wiring as I do my own (and it's shoddy and unreliable, at best). Cyclops is a good start, but I would think there should be someone up north who can help.

 

[nknudsen]

My conversion silencer

Here's a pic of my silencer after modifying the stinger pipe angle and adding a spacer to fit it to the new sub frame.

 

[nknudsen]

couple more pics

Here's a couple more pics of the silencer rework.