SOHC.co.uk Forums > CB500/550

DS full aftermarket exhuast system for the 500

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Oddjob:
The key to getting the 4 into 4 system to hang right is to fit them with the end joints missing at first. Fit the lower one first, remember that this bracket goes behind the frame hanger, fit the manifold clamp and collets very loosely so the front can still move around but can’t fall. Now fit the upper exhaust, bracket now goes in front of the frame hanger, so one each side, fit the footrest loosely. Look at the balance pipe at the rear of the exhausts, they should be directly in line with a small gap between them. Now move the pipes to allow this to happen, make sure the downpipes aren’t touching the frame especially on the left side, one pipe goes behind the side stand bracket and one in front. Once everything lines up, nip up the lower manifold clamp to fix it in place, loosen off the upper pipe until you can fit the rubber balance pipe, realign the upper and tighten the footrest bolts first, then the manifold ones. If you’ve got it right everything should look aligned from the rear with no twisting in sight.

McCabe-Thiele (Ted):
Thanks Ken I've saved your fitting instructions for future use - interesting that some brackets are fitted behind the frame.

bruxby-clive:
Many thanks for the fitting tips Ken, I have printed of a copy to help when I do fit them.

deltarider:

--- Quote from: Oddjob on January 06, 2023, 11:09:24 PM ---[...] ... and tighten the footrest bolts first, then the manifold ones. [...]

--- End quote ---
The idea is to avoid strain. So I have always thought that in the end, when everything is pretty well aligned, you tighten the manifold nuts in the front first and then the footrest as the latter's hole in the bracket, offer the assembly a little room to move.
Or, even better, prior to assembly, have the two 8mm nuts (on the inner side of the bracket) a bit loose and tighten them the very last, as at least one of the holes in the bracket, like the one for the 10mm bolt offers room for the assembly to move (see pic below). I've tested it and with the right wrench this can be done.

Oddjob:
You tighten the footrests first as they can sometimes move the exhausts into a different line, if you tightened the manifolds bolts before that it will cause the exhausts gaskets to leak as the force moves the exhaust header. A 10mm bolt will always exert more force than a 6mm bolt.

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