rm250z dg pipe

[zman]

has any one had any trouble with there dg muffler cracking around the weld where it bolts on the frame and where it joins on to the pipe

[suzuki43]

Yes mate,my mount broke in half where it bolts to the tank,pretty crappy welding.

[zman]

i bolted the muffler to the frame with out the rubber gromet in it the first time and it was solid. thats why i think it broke there wasn't enough give in it now ive put the rubber spacer back in it moves to much and is burning a hole in the side cover i cant freaking win. the hole in the top bracket is to big why they made it that big nothing fits right

[suzuki43]

Yeah I know,freaking Seppos!!

[zman]

so how did you fix yours

[suzuki27]

Try a washer each side of the mount- make sure the hole in the washer is a good fit with the bolt that will be going through them, that usually does the trick. There has to be some movement at the mounting points.

[SUZUKI311]

the hole in the top of the muffler is that large to cater for a rubber grommet. The correct size is available from MCS via any bike shop. Use a stepped washer with a large outside diameter and another large washer on the other side to prevent the muffler from moving around too much. Done correctly, there should be next to no movement of the muffler, but as suzuki 27 states, there has to be a little of give otherwise you get the cracking problems you are experiencing. i have had to use another spacer, approx 8mm thick,between the inner washer and the frame mount point to get the correct alignment. i also had to repack the muffler not long after getting it, the std packing goes out pretty quick.

[Rossvickicampbell]

Suzuki43 - see another problem with them yellow bikes - you actually start them and they begin to fall apart!

[suzuki43]

CMD its clearly due to the huge amount of horsepower generated by the mighty Suzuki,which is never an issue on a Red Lemon!

[zman]

ok guys  thanks for your help i will have another go at it at the weekend. see if i can make it work this time