Fitting New Mufflers

Seadog · Post by **Seadog** » Fri Apr 08, 2016 11:15 am

Yesterday, I received new mufflers for my CB77 from David Silvers Spares. In attempting to install them today, I am running into problems and I hope that members here can advise me.

Simply put, the mufflers just don't align with the mounting brackets. I believe that the bottom bracket is about an eighth of an inch out of alignment and if I do get a bolt through, the rear bracket and mounting hole are way off. It might be possible to enlarge the slotted holes on the bottom bracket and maybe bend them out a bit to make it work, but I'm not overly confident that it will.

I ask what your experiences are with mounting mufflers. Are modifications regularly required?

At this point, I suppose that I could return the mufflers - no harm has been done to them - but if modifications are commonplace and I am just over-thinking this, I guess I could take the risk and go that route. Please give me your advice.

P.S. Many thanks to Jensen for his detailed muffler how-to. With his information I'd have the work done by now, if not for the terrible fit.

revlover · Post by **revlover** » Fri Apr 08, 2016 11:40 am

It's possible your bottom mount or footrest brackets are bent slightly, mine are. They are somewhat vulnerable if the bike is laid down in an accident.

Seadog · Post by **Seadog** » Fri Apr 08, 2016 12:00 pm

revlover wrote:It's possible your bottom mount or footrest brackets are bent slightly, mine are. They are somewhat vulnerable if the bike is laid down in an accident.

Thanks, revolver, I can see how that might be a possibility, but my footrest bracket and the underside frame bracket seem straight. It wouldn't take much bending though and it's still a possibility. However, the bottom claw bracket on the muffler is very hard to get over the underside frame bracket. The distance between the claws seems just a tiny bit too close.

Hamamatsu Nippon · Post by **Hamamatsu Nippon** » Fri Apr 08, 2016 12:46 pm

According to Mr. Honda Bill Silver, the David Silver Spares mufflers are not a perfect fit. He addresses this in his ebay auction in the questions portion .

http://www.ebay.com/itm/262369425704?_t ... EBIDX%3AIT

Seadog · Post by **Seadog** » Fri Apr 08, 2016 1:05 pm

Hamamatsu Nippon wrote:According to Mr. Honda Bill Silver, the David Silver Spares mufflers are not a perfect fit. He addresses this in his ebay auction in the questions portion .

http://www.ebay.com/itm/262369425704?_t ... EBIDX%3AIT

Thank you, HN. Mr. Silver says that he does not use the upper rear mount at all, just the front and underside . I'll have to see if I can make it work that way.

Seadog · Post by **Seadog** » Fri Apr 08, 2016 4:09 pm

Well, I tried Mr. Silver's mounting method, using just the forward and mid mounting points. It attached without too much trouble, but the side stand jammed against the bottom of the muffler at about two thirds of the way up. No room for adjustment.

I reinstalled my old muffler, which took minutes. Now I guess I'll have to return the two I bought from DSS. Wish me luck with that.

Back to square one.

Seadog · Post by **Seadog** » Mon Apr 11, 2016 3:57 pm

I'm negotiating the return of these mufflers. What a mess. DSS wants me to try fitting the right side "Once I know you [sic] feedback regarding this I will know what to advise next."

I'm really glad I had the left muffler off though because I got a look at the side stand bracket. From my research of the side stand topic on this forum, it appears to be a Honda item, but the main stand mounting bolt was never changed to the longer part number 90146-268-810. Whoever installed the side stand put a cotter pin through the end of the short original bolt. No nut. Not good. I'm wondering if this is at least part of the reason that the side stand tips the bike too far over, although there is slop in the stand's pivot bolt. I'll need to remove it for a better look, but I need to find the longer mounting bolt & nut first.