New Member - Kerker Question

[ljasonb]

Hello everyone. I'm the proud new owner of Ben's (madmax-im) well cared for XJ.

I rode the bike 150 miles home and it performed well. I did notice that the exhaust was rattling. After searching the forum thoroughly, I've found tons of good info but didn't locate a thread that quite covered my problem.

Upon dis-assembly for cleaning and inspection I found the end cap, baffle, and what I'll call the "solid section" all disconnected from each other and shaking around freely inside the muffler. Looks to me like all three sections were once welded together - end cap to baffle to solid section. However, I can't find mention of the solid section here on the forum. So...

What's supposed to be welded to what?
Anybody else using this solid section?
My solid section has a crack on the inlet side. That a big problem?

Thanks in advance everyone. And, thanks Ben for taking good care of your XJ. It's in good hands now.

-Jason

[BA80]

Welcome Jason. Yeah, you gotcha a good one I think.

I had that exact exhaust on my SG when I first got it. You've got a helluva lot more with that one than I had. All that came with mine is the megaphone and that piece of pipe there in the front. I McGyvered a baffle and an end piece for it.

Eventually got rid of it and went with a Mac 4 into 2.

I think your best bet is to get some SS packing and pack it in there tight enough to stop the rattle and start looking for another exhaust. Kerker ain't around anymore.

[ljasonb]

I have my eyes open for another exhaust but I do like the Kerker. Pretty sure I have all the pieces to make it work fine just hoping to confirm how it all goes back together.

Definitely gonna re-pack it. Is there general agreement on steel wool vs fiberglass?

[BA80]

Not steel wool, stainless steel wool. Regular steel wool wont last long at all.

JCWhitney has it fairly cheap.

[WMarshy]

You want the steel packing... you can use almost anything you want but I think the stainless steel holds up better. At least, thats what my buddy that rides a dual sport says. You should be able to get it from any bike shop, the off road bikes use it and should be fine for your application. I think a lot of people got tired of either repacking those Kerkers or just wanted more noise (or less rattling) and removed the baffle...

Welcome to the forum.

[bikerphil]

I would first find which end of the solid pipe fits in the end cap, then fasten the long baffle piece to the other end and then install back into the can. I have the same setup but I don't use any fiberglass packing.

[BA80]

I would first find which end of the solid pipe fits in the end cap, then fasten the long baffle piece to the other end and then install back into the can. I have the same setup but I don't use any fiberglass packing.

That hurts my ears just thinking about it Phil.

[jayel]

another source of stainless steel to use for packing is pot scrubbers, really cheap at wally world just stretch them out and wrap around the inner pipe

[bikerphil]

It's not that loud with the baffle, sometimes I run without it, then it's a bit loud. Still quieter than a HD noise pump.

[BA80]

I ran mine without the baffle...................once. Thought my ears were gonna start bleeding.

[daveyg]

My bike came with a kerker but it's significantly rustyer inside than the pieces u show there, and that solid baffle piece is nowhere to be found, and as I haven't got the scoot running yet I'm not entirely sure how it'll sound, I'm afraid without anything securing it the front end of the baffle will rattle around against the outer pipe like nobody's business... But just now I have the sneaking suspicion that perhaps that piece is merely stuck inside and rusted into one piece with the outer pipe? Anyway, I'm interested to see how yours ends up. I have thought of (and started collecting necessary pieces) fabricating my own x-pipe style fully titanium exhaust however... Well, good luck with your exhaust rehabilitation! Keep us posted!

[ljasonb]

another source of stainless steel to use for packing is pot scrubbers, really cheap at wally world just stretch them out and wrap around the inner pipe

We talking Scotch Brite pads?

[madmax-im]

Hi Jason welcome to CH11...glad you are posting...I always thought the muffler needed repacking as it is a bit loose when you blip the throttle. The Kerker is a very good exhaust for this bike. Very hard to find anything new for these bikes as the only manufacturer still making an aftermarket exh. is MAC and they are cheap even though they arent cheap...if ya know what i mean. The OEM exhaust which I had up until 2007 was totally shot...... I then went with a MAC and later a Jardine...and now the Kerker. I searched a good 3+ yrs looking for a Kerker.

[ljasonb]

Thanks Ben. I like the Kerker too. Just gotta get it buttoned back together correctly. Do you know if all three sections were welded together originally?

[madmax-im]

Thanks Ben. I like the Kerker too. Just gotta get it buttoned back together correctly. Do you know if all three sections were welded together originally?

Sorry Jason I havent a clue...being kind of ignorant abt it...I just put it on and assumed it was fine...with my poor hearing i never heard it rattling although it prolly was. I had a local XSive tell me it was rattling and to repack it with fibreglas...which I was eventually going to do.