Kerker

[Ranger_xs1100]

Hello Everyone,

I have a Kerker exhaust system that I’m thinking about selling, but before I do I’m trying to find out if the baffle is supposed to be loose in it or not. I don’t want to sell a faulty muffler.

The brown baffle part that sticks out the front of the muffler where it joins the pipe is loose. I can slide it in and out of the muffler about one inch. It seems solid enough, I just don’t know if it should move in and out like that or not. And if not, what would be the fix for it? Perhaps just some sort of packing?

Thanks in advance for your help!

[rdmcguy]

Kerker

Ranger, I have the same system on my 11 and the interior pipe on mine is completely dislodged on mine it moves in and out a couple of inches, I don't know how it is SUPPOSED to be but mine works just fine , I tried to remove the end cap and baffle from mine but would have to destroy baffle in order to do so ,There are aftermarket baffles available ( I have one) but I just live with that purring growling throaty roar !

[Ranger_xs1100]

Thanks Guy. The kerker came with my non-running 80 special parts bike so I have never heard what it sounds like. I'm guessing that as long as it doesn't rattle it should be fine.

[DiverRay]

The baffle is bad if the pipe is sliding out. Run it another 2K miles and you WILL know it! I ended up building a baffle for the kerker that was on my '79 Quail Bike. It was easier and cheaper than trying to get a GOOD baffle for it.

[Ranger_xs1100]

baffle

The baffle is bad if the pipe is sliding out. Run it another 2K miles and you WILL know it! I ended up building a baffle for the kerker that was on my '79 Quail Bike. It was easier and cheaper than trying to get a GOOD baffle for it.

Thanks Ray,

I pulled the baffle and cone out and it is a bit rusty, not too bad though,
but I'm sure you are right, it's just a matter of time.

What did you build your own baffle out of?

I didn't peel back all of the insulation but
It looks like just a piece of pipe with a lot of holes drilled in it?

[DiverRay]

I used a 1 3/4" exhaust pipe, cut most of the way through so I could bend it and weld a brace to keep the same angle as the muffler. I then cut a few slots and bent them down to force the gases around the pipe, and on the exit side I did the same, only made to help the gases escape. I then drilled a bunch of 1/4" holes in the end of the pipe, and wrapped steel wool and tied it with wire to keep it in place.
Worked well, and was somewhat quiet. At least the neighbors didn't complain.
Let me see if I have the photo's around, and if so I'll post them.

[DiverRay]

OK, found the photo's of the baffle.
[IMG]/IMG]
The baffle as built.
[IMG][/IMG]
The cut for the angle. I used the MK1 eyeball to insure accuracy.
[IMG][/IMG]
I had to grind out the aluminum cap for the larger pipe.
[IMG][/IMG]
This is the input side. Note the flat sheet steel rolled to keep the pipe centered in the muffler can.
[IMG][/IMG]
The packing at the output side. One thing I did that's NOT pictured is I put a hose clamp about 1/2" in from the end of the pipe. That keeps the pipe tight to the outlet cap. and allows me to tap the other end of the pipt to remove the cap.

[Ranger_xs1100]

Ray,
That is quite and ingenious fabrication!
I'll be stealing (I mean borrowing) some of your engineering!
Thanks.