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Help How the hell does this muffler come off?

Discussion in 'Kawasaki 250cc In-line 4's' started by DamnitLaverty, Sep 16, 2016.

  1. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    the muffler is kinda in the way of the rear brake caliper, or moving it easily to work on it anyhow... how the hell does this flange thing work? I unbolted the hangar, lightly banged on the flange and muffler- nothing seems to move. What's the trick? The manual was no use, but I did look there first lol.
     
    DamnitLaverty, Sep 16, 2016
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  2. thebeefsalad

    thebeefsalad Well-Known Member

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    Try giving it a twist.
     
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    thebeefsalad, Sep 17, 2016
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  3. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    Word. The flange didn't look like it would allow that. I gave it some gentle twists- I'll get on it harder. Thanks.
     
    DamnitLaverty, Sep 17, 2016
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  4. pkay

    pkay Junk Accumulator

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    If its a slip on I will spray a bit of bolt unfreeze spray at the join. Comes off easy then. Otherwise yuou can always slacken the pipe off at the header and disconnect the rear mount if your are trying to get to the rear brake.
     
    pkay, Sep 21, 2016
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  5. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    Nah it's then stock setup. If it was a slip on it'd be done already. ;)
     
    DamnitLaverty, Sep 21, 2016
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  6. kiffsta

    kiffsta Senior Member

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    did you undo the 3 bolts on the flange that holds the end can on ?
     
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    kiffsta, Sep 21, 2016
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  7. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    I thought they were studs! Seriously?!? Maybe mine are just really rounded off lol
     
    DamnitLaverty, Sep 21, 2016
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  8. kiffsta

    kiffsta Senior Member

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    That will be your problem then
     
    kiffsta, Sep 21, 2016
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  9. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    IMG_5207.JPG Yeah. This is what I have. This is why I thought it was studs- there's no way I can get this ring off, so I thought it was a cover for studs and the muffler lowered onto studs and a gasket and was held in place with the hangar bolt pressure.

    The hell does this ring come off? You can see where I've already pooched it prying on it...
     
    DamnitLaverty, Sep 21, 2016
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  10. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    For what it's worth- for all this effort I've just been working behind the muffler. Rather, I'm waiting on parts and packing for a trip to Europe so it's been sitting... but at this point it's an academic exersize not a necessity. After measuring it at 118db in my garage at 15k the other day I don't think I ever need to worry about removing/replacing it with something louder.... ouuuch
     
    DamnitLaverty, Sep 21, 2016
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  11. kiffsta

    kiffsta Senior Member

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    I have never seen anything like that as a cover

    zxr250_headers.jpg
     
    kiffsta, Sep 21, 2016
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  12. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    Hahahhhaa welcome to why I'm so freaking confused!

    Do I just have some magical piece of unobtanium JDM alloy that hasn't been seen since 1991 when the first owners of these bikes serviced them and threw the bits away?! Craziness!
     
    DamnitLaverty, Sep 21, 2016
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  13. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Any bolt's on the back of the muffler that hold the tip on ?
    If so they might be long bolt's with nut's on the end, that flange might have stud's welded to it then they slide into the muffler, and the bolt's that hold the tip on go all the way to the front of the muffler and hold the lot together ?
     
    my67xr, Sep 21, 2016
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  14. kiffsta

    kiffsta Senior Member

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    There looks to be a bolt hole down low, is there a bolt around the back side ?
     
    kiffsta, Sep 21, 2016
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  15. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    Nada! I'll get some close up video tomorrow for you guys. I'm in bed now. :)
     
    DamnitLaverty, Sep 21, 2016
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  16. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    Back from the dead- finally got around to this. Turns out that cover was tack welded to the bolts. :-/

    Bolts came right out once I broke the welds on the cover.
     
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    DamnitLaverty, Aug 25, 2018
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  17. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    I was about to write that it looks like someone welded a cover on it.
     
    maelstrom, Aug 25, 2018
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