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[ric]

I run with the baffle in, but only with the innermost set of tangs in use as I think it seems to produce a slightly better tone. I'll post a pic of the bike when I get back to Blighty next week.

[Rattlebattle]

Thanks.

[jefrs]

I have got my 50's silencer very close to the swinging arm, so close at first that I had to pull it out to clear the brake pedal lever. The required a slight S-bend put into the silencer's bracket bar. It hangs from the frame's exhaust mount not the footpeg. To get a good fit and seal at the head I had to nip up the down pipe first with the silencer off and then rotate it with the silencer on, before clamping up hard with the torque wrench. The 50's system terminates with a cone into the head and this can go in a bit sideways (not good). Do use a torque wrench and check visually that it is square-on. I used two copper gaskets *** p/n "582638/A" *** - because with one the flange almost butted against the head, it must press on the gasket; less noise, more poke. The copper gaskets are not expensive so I got several in case I take the exhaust off again as they're not re-usable; they have been on and off a few times. Cleaning the black hole out with scraper and port brush was a good plan as I found a lump of good coal stopping the new gaskets from sitting down.



I got a second 50s down pipe when I fitted the Autotune AT-200 because it needs a much larger O2 sensor (Bosch wide-band). The chap who did the MIG welding found the pipe was already drilled for the larger 'bung' when he ground off the smaller one. The first pipe I had actually fitted to the bike better than the second one, there is some variance in manufacture.

[ric]

91130 exhaust system - with added tweaks 2015 B5

[Rattlebattle]

Thanks for posting pics; I reckon I'll give mine a tweak. It must be perilously close to grounding.....

[Deanobats]

I also bought and fitted a UK exhaust (part number 91130) to my B5 Bullet. I found the supplied bar which connects the exhaust to the back of the foot peg far too long - this was Hitchcock's suggested mounting point. The silencer dipped at an alarming angle. Shifting it to the old exhaust mounting bolt is a very smart idea, but I was a bit worried about the angle of the bar, it might act as a lever and loosen. In the end I drilled a second hole in the bar about 20 mm up from the first so that I could hang it more or less vertically from the back of the rear foot peg. However, I instantly regretted this as the bar is made from some kind of space-metal and I melted three HSS bits with hardly a mark. I should point out that I didn't have a pillar drill, just a black and decker in a drill stand, which was a bit silly. In the end, I managed to get a small pilot hole through it and gradually widen it with masonry bits till I could get the 8mm bolt through.
The new exhaust is a miracle. The power delivery is smoother, there is less vibration and the bike feels much more responsive.