81 XS1100sh modification question

[RichV]

As most have to, I am using a non-standard set of mufflers on my rebuild with original pipes. They're a set of HD mufflers I have around the shop in great condition and the right size. Unlike the originals these mufflers are the same diameter all the way to the end where they taper a bit. The left side mounted no problem. The right side, however, had a clearance problem

The bridge of aluminum that extends below the rear brake peddle mount pushed the muffler down way too far. I want them to be lined up with the aluminum bracket but the pipes were pushed down (unlike the left side). I can't stand uneven pipes and this produces a two inch difference.

So my idea is to cut this bridge off. I don't see how this can cause a problem but with my inexperience on these bikes I might be missing something. So I modified a second bracket I had laying around (unusable due to other mods) to test it out. With that change I was able to mount the muffler even with the left.

So is this an okay approach? It looks like it will work fine. Here are two photos showing the modified bracket installed and the improved clearance alone with a photo of the bracket I will be modifying.

The only stress point I can see if from the muffler mount and a passenger's foot on the peg. Unlike the left side, there are two bolts holding the back part of the bracket in place.

[mrhammer2u]

It's just a bracket for the rear foot pegs. I actually had mine completely removed and then shortened the 1 bolt that goes all the way through. I have a solo seat.

[jetmechmarty]

I'm not sure about this, but I think it's going to break opposite to where you cut away. The foot rest mounts on the end, secured by a long engine mount bolt, correct? What keeps the foot rest from pivoting?

[James England]

What happens when you press your foot on the brake pedal? What's stopping the splined shaft from dropping down when you press through lever?

[mrhammer2u]

I've seen others that have shaved or removed their's as well. The rear brake is a lever motion so there is no direct down pressure. So far I've not heard of any complaints. Have not yet ridden mine since removing so I cannot personally say.

[MPittma100]

The Worst?

As most have to, I am using a non-standard set of mufflers on my rebuild with original pipes. They're a set of HD mufflers I have around the shop in great condition and the right size. Unlike the originals these mufflers are the same diameter all the way to the end where they taper a bit. The left side mounted no problem. The right side, however, had a clearance problem

The bridge of aluminum that extends below the rear brake peddle mount pushed the muffler down way too far. I want them to be lined up with the aluminum bracket but the pipes were pushed down (unlike the left side). I can't stand uneven pipes and this produces a two inch difference.

So my idea is to cut this bridge off. I don't see how this can cause a problem but with my inexperience on these bikes I might be missing something. So I modified a second bracket I had laying around (unusable due to other mods) to test it out. With that change I was able to mount the muffler even with the left.

So is this an okay approach? It looks like it will work fine. Here are two photos showing the modified bracket installed and the improved clearance alone with a photo of the bracket I will be modifying.

The only stress point I can see if from the muffler mount and a passenger's foot on the peg. Unlike the left side, there are two bolts holding the back part of the bracket in place.

What's the worst that could happen if the modded bracket cracked/separated above the brake lever?

http://www.partzilla.com/parts/searc...EST/parts.html

[RichV]

I'm not sure about this, but I think it's going to break opposite to where you cut away. The foot rest mounts on the end, secured by a long engine mount bolt, correct? What keeps the foot rest from pivoting?

There are two bolts holding the back half of the bracket to the frame. That will prevent the bracket from twisting from pressure on the back foot rest.

What happens when you press your foot on the brake pedal? What's stopping the splined shaft from dropping down when you press through lever?

The brake spindle mount is part of the frame. The brake will operate without this bracket being in place. The purpose of the bracket is to provide the passenger footrest and a mounting point for the muffler. That and style.

Thanks everyone for the input. I'm going to do it but only take out only what I need to give the muffler the proper clearance. I really didn't want to do it at all but I can make it look like it's part of the original design.

[jetmechmarty]

I wasn't concerned with the rear foot rest, but the possible twisting motion applied by the front rest.

Is there an option to lower the left side to match the right?

[RichV]

I wasn't concerned with the rear foot rest, but the possible twisting motion applied by the front rest.

Is there an option to lower the left side to match the right?

The front foot rest is independent from the bracket with both attached to the rear engine mount. There is a stop on the frame that prevents it from rotating.

The pipes would need to be modified to allow the muffler to be lowered to match. I'm not good at bending pipes.

[crazy steve]

Those brackets on the Specials can break even if they're not modified, so don't be surprised if it does break. Have you thought about carefully 'dimpling' the muffler like Yamaha did? The right-sized socket (with an extension for a handle) and a dead-blow hammer should do the job neatly. Put some masking tape over the area; that will allow you to easily mark it and help protect the chrome.

[James England]

The brake spindle mount is part of the frame.

ah, different from the European version then, where the alloy hanger is the support for the spindle. That's what had me worried re what would happen when the lever was pressed.

[DiverRay]

James,
The EU models have our "standard" type features, and our "special" really is...
I know, been working on a '79 standard, and need to get the '80 Midnight Special out of mothballs and ready to ride for the Quail Motorcycle Gathering in May.

[RichV]

Those brackets on the Specials can break even if they're not modified, so don't be surprised if it does break. Have you thought about carefully 'dimpling' the muffler like Yamaha did? The right-sized socket (with an extension for a handle) and a dead-blow hammer should do the job neatly. Put some masking tape over the area; that will allow you to easily mark it and help protect the chrome.

I didn't think of that. I would probably have to make a larger dimple on these HD mufflers since they aren't tapered like the originals. Maybe a combination of the two.

[RichV]

Follow-up:

I modified the bracket and mounted the muffler. Here's some photos showing the results. I think it turned out well.