DS full aftermarket exhuast system for the 500

[mickwinf]

I too will be buying a set for lazarus, and have noticed Silvers lists 2 options, a bare set and one including the brackets, gaskets and rubber connectors for only £45 +vat so good value if you need the full lot. Assuming the exhausts are the same of course.

[McCabe-Thiele (Ted)]

I too will be buying a set for lazarus, and have noticed Silvers lists 2 options, a bare set and one including the brackets, gaskets and rubber connectors for only £45 +vat so good value if you need the full lot. Assuming the exhausts are the same of course.

Full Monty with brackets.

[Oddjob]

Sorry to be the prophet of doom here but some reports of the DS brackets not being exactly the ride shape (as in bend) to get the exhausts to hang correctly. I compared my original brackets with my BILs DS copies and had to rebend the DS ones so they matched the OE brackets, he couldn't get his exhausts to hang right at the back with the DS copy brackets, they hung right after being rebent to shape.

I seem to recall Ash doing a comparison some years ago which made me check the BILs when he popped round on the 500.

Get original IF you can find them is my advice.

[Seabeowner]

Ok here is my experience of the DSS 4/4. Mine have been fitted a while ago.  Ordered in 2016 (£850 then), but not fitted until early 2017. Three problems: Had to bend the hanger (original Honda bracket) for the lower left to get it in place, Even then the hang at the front end was not entirely correct as the pipes spacing was a little uneven. (no one has spotted it but me): There was a leak of exhaust gas around the 8mm studs that come out of one or two of the silencers so I used a tiny amount of Gun Gum, solved: the main stand stop was about 2cm out, so I made a little extender plate.
Just taken them off for the first time after 6 1/2 years. Only covered 3500 miles but they are still in first rate condition and come up like new.

Ordered a set from Busso this year to assess their quality but their delivery is poor. Was promised 3 months and it's now been 6. Note: They charge 150 Euros for international shipping.

[McCabe-Thiele (Ted)]

Although my experience is much wider on the car front I know even factory original replacements often did not always fit perfectly on BLMC, Vauxhall's, Opel's, Audi's, Mitsubishi and Mercs  brands.

Dam it the exhaust on my 400 was a pig to re-fit so I am expecting to have to either bend a bracket, widen a slot or fit a spacer - I see it as par for the course.

[deltarider]

The repro 4-4s seem to produce an even better sound than the OEM ones did, at least in my ears. I agree that the extra cost is more or less the same amount your bike will raise in value. The CB500 exhausts were by far the nicest, most elegant ones in the whole SOHC CB Four line. Next spring I hope to use my restorated CO-meter to fine tune each carb by monitoring each of the 4 exhaust and that is impossible with a 4-1. A trained ear can even hear/compare the differences in sound. It is how the bike has been designed originally.
I'm still trying to establish the best way to disassemble and... assemble them and by that I mean the working order. I have been helped much by Sohron, but unfortunately his info was not complete. At 2/3 from the beginning in: http://forums.sohc4.net/index.php?topic=151576.0
Over the years I have put of and on mine (two sets) about six times in total. Sohron has made it clear that the top of both brackets (the upper and lower) is to be at the opposite side of the frame eye. That was new to me. Most of the years I have had them both on the outside of the frame eye and - although this is quite possible* - the result is not as nice as to have them on opposite sides.
I have been quite unfortunate with the 6mm studs in front. Many years ago I had been tempted to use my then new torque wrench. It worked fine, but I will not do it again. On later (dis)assemblies I was plagued  by studs that either turned in the head or gave other problems. It was as if that torqueing in the past has had its toll later on. The studs seemed old and fatigued and quite a few needed to be replaced by time serts. By stupidity I have managed to mishandle the lower bracket LH side and as a consequence that side has both brackets on the outside again. Aaaargh! Although it's hardly noticeable, the result is the #2 pipe touches the sidestand mount and not all ten bolts in the oil pan are equally accessible. Maybe one should, before mounting the exhausts, also loosen the two nuts that secure the brackets to the pipes just enough, so they can slide a bit. The design of the holes in the brackets seem to suggest that. That's then another thing I have overlooked. Personally I'd hesitate to fasten the 8 nuts at the headers last. I have had more than enough of these studs going bad.
* One of our CB Four specialists in Holland doesn't bother. He just mounts both brackets on the outside of the frame eye. 

[Seabeowner]

Revisiting the fit of the repro 4/4 today after 6 1/2 years as I have my original K0 to compare it with.
The sweep of No. 2 pipe is about 5mm too low along the underside of the bike. This causes the pipe to clash with the nut on the back of the sidestand so that the pipe is too far to the centre of the bike and runs closer to the oil filter case.
I can fit a half nut to the side stand but this will only help fractionally.
No idea if this is representative of pipes made today.

[Oddjob]

I think you bought the first repro system that came out, it’s possible the later systems have been altered to avoid those problems, we’ll only really know when someone with a recent system fits it and gives feedback

[Johnny4428]

That’s what happened with me with the K3. Had been looking for a set for years when they finally came on the market I was quick to snap up a set. With the result I had to use a couple of ratchet straps to fit them.
And that was with the original brackets. Too quick to jump in but didn’t know how long they would be available at the time. Pleased with the quality though.

[deltarider]

[...] The sweep of No. 2 pipe is about 5mm too low along the underside of the bike. This causes the pipe to clash with the nut on the back of the sidestand so that the pipe is too far to the centre of the bike and runs closer to the oil filter case.[...]

What you describe, is exactly what I have and my exhausts are OEM. I blame it on my mishandling of the lower LH bracket which forced me to have both brackets on the outside of the frame eye again. However, having them both there, is not the cause in itself. I have had both brackets on the outside of the frame eye before for many years and then there was no problem. These exhausts need constant attention when you mount them. As I see it, everything must first be not completely fastened but pretty close to it. Always realise the studs in the front are the weakest of all fasteners. Before fastening, you need to inspect in particular how the #2 pipe runs near that mount of the side stand. Also see to it all ten oilpan bolts are accessible. The latter will always be a close matter, but, hey, that's the beauty of the design.

[Seabeowner]

Just to confirm delta, the brackets definitely go on opposite sides of the mount. A problem arises as if a lot of two up riding is done the mount can get bent.

[deltarider]

Just to confirm delta, the brackets definitely go on opposite sides of the mount.

Yep, I've learned this from Sohron. I remember asking him if his method would also apply for the CB500.

A problem arises as if a lot of two up riding is done the mount can get bent.

I'm afraid I don't quite understand what you mean. Is there a danger of bending with both on the same side or on opposite sides?
I'm asking because in the real world I have seen more CB500s having both brackets on the outside than on opposite sides.
The way Sohron suggests certainly gives the most elegant outcome. My RH side is perfect and the oilpan bolts on that side are just accessible.