My first bike show...

[Kwakked Up]

Thanks Dave

I thought the prices at dynoman for the full system were as competitive as those Ive seen on fleabay

Now I just gotta get rid of the zx10 so I can spend more $$$ on the z thou project

[jacobb]

Hey Dave,

Got the Kerker on a couple of weeks ago, I had the bike on a stand without a front end for about a month as I had to replace the front forks (the stanchions had hugs pits that couldn't be fixed and I had to wait to get whats called a handle bar stopper from Japan, as the previous owner had just overtightened the fork top bolts to hold the handlebars down) , bloody ridiculous. Any way, will post some photos soon... It looks great but doesn't sound as good as expected...

Out of interest what size baffle came stock with yours?

[kawadave]

Jacobb...I too was very disappointed with the sound of the standard baffle that came with the Kerker.

Mate,get yourself a Medium 2.0" Competition baffle,and you will be well impressed.
I think the 2.5" would be to loud for street use.

This is were I purchased mine......http://dynoman.net/exhaust/baffles.html

[jacobb]

Yeah I reckon I'll order one of those!

So here she is, took her for a ride today, wasn't the most successful

1. lost a side cover, turned round in time to see a car drive over it _ FAIL
2. Found a crack in my clutch cover and was spraying oil over my rear brake pedal... Will need to get another one

On the good side she is riding really well - the forks are gold and don't leak a drop and the motor is strong and quiet!! Can't wait to sort out the finally nigly bits. So what do you think of the exhaust?

[kawadave]

The zorst looks great Jake...

When you get yourself a baffle, give me a shout and I'll tell you how to go about changing it.

[Gosling1]

that zorst looks the goods alright......shame about your sidecover though - typical of all those old sidecovers though, I have lost count of the number of sidecovers I have lost and then retrieved......

Easy fix though - just use a 2mm drill, mark the mounting lug on the inside (while its fitted to the frame) - with some white-out or white paint. Take off the sidecover and you can see where you need to drill the hole - on the painted section of lug, as close as possible to where the paint stops - then use a small D-clip or a split-pin etc - placed through the hole once the sidecover has been re-attached. Bingo - no more lost covers. I normally only do the top 2 lugs, although you can do all 3 if you want. New rubber grommets help, but are not fail-safe......clipping the covers on is the best bet.

I need to order one of those better baffles for the Kerker fitted to the Black Pearl - it is really quiet....

[jacobb]

Ahhh yes... Good idea Gos! I was thinking of skinning the cat a little differently maybe getting a bit of metal trace, looping one side to frame - crimp it off and looping the other side to a hole drilled in the bottom edge... So I can pull them off with wire attached, but if they come of they'll be tied on!

[jacobb]

So ended up getting that baffle Davo, Any tips on getting it in...?

[kawadave]

Jacobb...it will probably pay to put some grease around the new baffle and pipe to help it slip in easier.

"That's what the prostitute said to the sailor"...BTW.

Make sure the screw hole lines up correctly and jobs done.

I guarantee you-ll be impressed with the new note.

[jacobb]

Did you have any trouble getting the old one out - I had a brief fiddle and it seemed pretty stiff (no prostitute involved)

[kawadave]

Once you have the tail pipe off...you will notice that the original baffle/insert for Gos sticks out the bottom of the pipe.
Just hit the old baffle out from the front of the pipe ,using a piece of wood and a FBH.

Alternately ,just bang the tail pipe on the ground and the baffle will pop out.

[Gosling1]

yes, I like a good insert

Jacob - I just gave the long skinny end of the baffle - shown in red above in Dave's photo - a good 2 or 3 smacks with a piece of 4 x 2. This was plenty to get the baffle moving out of the tailpipe - once it starts to move it gets easier with each belt.

The new baffle should slide in pretty easily, just make sure you line up the hole properly so the screw at the end fits properly....the new baffle slides down inside the tailpipe a few cm.....and yeh, the note is *so* much better than what you get with a stock Kerker.

[jacobb]

That's awesome, thanks for posting that diagram Dave - couldn't be much clearer than that. Since last week I haven't had any luck - got the baffle in the post and the guys at supertrapp packed it before the paint was dry, so there were patches where the paint had stuck to the plastic bag it came in, so I had to sand it back and paint it with high temp paint. That takes 7 days to cure, so I can't put it on till saturday...

On top of that, my charging system was not charging the battery so I bought a generator and went to put that only to find that the magnets on the rotor were cracked... how did that happen?? So I have gone off and ordered a new rotor - got to wait till that arrives.

Do you need that rotor holding tool that is in the workshop manual, or can you get away with it being in gear and someone standing on the rear brake?