Suzuki 2 Strokes

After 6 months on the maintenance stand, the bike is finally on the floor. Suddenly, it looks dinky. Kinda like a low rider
Now comes the treat of TRYING to hang the exhausts. I bought new clamps and rubbers for the center junction. I wish I had kept the old rubbers. These new ones are super tight. So tight in fact I may never get the pipes on. I have to stretch them to get them on the header pipe. When I do that, it forces the larger end to fold / tuck in on a hole that is already too small. Is there a trick? I thought maybe I got the wrong ones, but the part number for the 380 is the same. P.S. the block of wood on the head means nothing.

Looking good!

Try heating them with a blow drier. Before they cool off, hit the insides with a lubricant. A lubricant that will dry away. WD-40 for example.

Hi,the trick is to fit the rubbers to the exhausts..not the header pipe ! spray with something like WD40 or the like & it won't be a problem,works every time on my 750 I'm sure this fitment method is mentioned in my Haynes manual OR you're try to put them on the pipe the wrong way round
Cheers,
Roger

Put the rubbers/clamps on the center mufflers first then slide them onto the header pipe. Might need a bit of lube on the ID of the small end. Snug up the bolts on the center pipe where it bolts to the cylinder first. That will hold the header in place and you can work the mufflers on.
She's starting to look like a bike again! Nice work!!

Anybody ever tried flipping the bike over to do the job? I've been toying with that idea in my feeble mind.. I have filled the transmission, but if the o-ring on the cap is good and I cap off the breather pipe--------hmmm. Oil tank and brake hydraulics are still dry.

Hi,a little awkward to do whilst lying under the bike....my biggest problem is getting back up again must be getting old
Roger

I got my exhausts together by putting a load strap around all 3 and ratcheting them together. Plenty of lube on the O rings.

Alan H wrote:I got my exhausts together by putting a load strap around all 3 and ratcheting them together. Plenty of lube on the O rings.

I've done the same thing. I lubricate the o-rings with three-bond which helps the sealing as well.


Lane