1980 XS1100 Special SG Model Exhaust Fitment

[MrJosephS]

Has anyone had any experience, or success, swapping out their 1100 stock exhaust for a Mac 4 into 2? This system has the "flare-tip" style mufflers.

Seems almost impossible to get the muffler mounting points on the right to align without bringing exhaust header in contact with other parts of the motorcycle first, namely the foot-brake arm.

On the left, the "side-stand" does not clear the muffler.

Additionally, I had to remove the center stand because it too made contact with the mufflers.

Factory says the system is a direct fit and all stands should remain?

Have forwarded photos to the factory but not real hopeful I'll get a quick response.

Joe.....

[madmax-im]

I'm not an expert but isnt there a difference between the Std and the Special? If so it sounds like you have the wrong exhaust...but dont take my word for this...would like to hear some true experts weigh in ...

[BA80]

Has anyone had any experience, or success, swapping out their 1100 stock exhaust for a Mac 4 into 2? This system has the "flare-tip" style mufflers.

Seems almost impossible to get the muffler mounting points on the right to align without bringing exhaust header in contact with other parts of the motorcycle first, namely the foot-brake arm.

On the left, the "side-stand" does not clear the muffler.

Additionally, I had to remove the center stand because it too made contact with the mufflers.

Factory says the system is a direct fit and all stands should remain?

Have forwarded photos to the factory but not real hopeful I'll get a quick response.

Joe.....

I have a flare tip Mac system on my SG. No fitment issues at all.

I built muffler brackets out of aluminum stock bar from the hardware store.

The flare tip system is the only 4 into 2 Mac that has removable baffles. I cannibalised mine and built my own straight through baffle system.

[BA80]

I'm not an expert but isnt there a difference between the Std and the Special? If so it sounds like you have the wrong exhaust...but dont take my word for this...would like to hear some true experts weigh in ...

The Mac doesn't really give a choice, 1 system 1 part #. They are a bit long for the Special and the muffler mounts are a bit too far back but if you shorten up the collector or just push the muffler further on it's close.

My home made baffles butt right up to the collectors inside so I just built my own hangar brackets from aluminum stock. The further back the exhaust exit, the quieter it is for the rider.

[MrJosephS]

Exhaust fitment

Thanks Greg,

But would you address the side and center stand issues. I just don't see any clear way to avoid these two stands coming in contact with the pipes. Additionally, the "L" bracket that is supposed to bolt to the slotted fitment point on the left muffler to prevent the center stand from making contact with the muffler, is not long enough to accomplish this. Crap, a newly fabricated "L" bracket would require it to be considerably longer than the one provided and would locate the center stand dangerously close to the ground in order to avoid contact with the mufflers. The left muffler does not look like it will sit in the cradle of the center stand to give you ample room to depress the foot plate, the point where you place your foot on the center stand to actuate the lifting mechanism. The foot plate actually intercepts the center of the muffler on the bottom. Finally, why did you have to make new aluminum brackets for the mufflers if the factory claims the system is a direct fit?

Thanks Joe........

[BA80]

There's no way to keep the stand levers from hitting the exhaust. The way I dealt with it is to wrap the levers in rubber, heater hose worked for me, so they aren't just hammering on the mufflers.




I extended the lever on the side stand to make it easier to catch with my foot.



My brake lever clears the pipes just fine with them adjusted in a little. It's been a while since I put the Mack system on but I think I might have actually bent the brake lever outwards slightly to get some extra clearance.



If I can help more let me know.