The other Brute...

Well, not bad at all to remove. About 30 minutes.



And of course it's not the gasket.





Decision time...

Another one of these or something else.

Its a bad design Lee. The pipe is solid between the engine and the frame so any twists or movements in engine /frame result in the torque being applied to the exhaust pipe. Something has to give eventually. Hey I know a guys that got one...oh wait ..no I got that one LOL

X2 on the design. When I loosened the muffler it moved away from the frame so it was 'in a bind'. When I put it back together (going stock) I'll shim and space as needed to secure the muffler where it wants to be. I have considered butchering the old muffler so I can weld in a second slip joint for the rear pipe (like the front has).

I'm not biotching about the repair. I have a lot of fun with that machine. It's well worth it. But I am going to write Kawie. Fire hazard in many ways - that big gas tank right behind it - before the spark arrester - G Bob had this problem, etc... Probably come to nothing but will be a nice distraction.

When I put mine back together I bolted the pipe on the cylinder first and sure enough the hanger holes didnt line up. If I use the stock hanger holes it will be in a bind. I decided to rig mine this time. I put a couple pieces of mine belt between the hanger and the frame and used heavy stainless hose clamps to hang the muffler. Dont know how well it will hold up but I'm gonna try it and see.

That sounds like a good idea G!! Give it a little room to flex

Thanks for the idea Bob! Gonna do something different - that's for sure!

Done. All fixed up. I also replaced the steering shaft bushings and spark plugs. That back plug is STILL a biotch to change. I feel the muffler mounting is in better alignment now. Used a few spacers to let it be where it wanted to be. We'll give it another 3500 miles and see how it does!

...... ......

Steering shaft bushings..why didnt I think of that arrrgggggggg...

Ok Lee...looked thru the exploded view...what are you calling a steering bushing? My shaft is definitely loose but the only thing I could see to replace was the steering clamp?


http://www.bikebandit.com/houseofmotorcycles/2009-kawasaki-kvf750d9f-brute-force-750-4x4i/o/m17939#sch578863

P/N 92171 in the blow up.
There might be aftermarket ones that are bigger. Would have more wear surface and might be greaseable with a zerk.

Yea clamp. That's it. 2 pieces. Tightened mine right up. They are a 'non-metallic' wear material. My handlebars had some play in them and replacing these corrected it. I was able to access them buy removing just one piece of the left side plastic. Not all that bad to do.

ok...thats the only part I could see that I thougth would tighten it up. By the time I get this thing back together its gonna be like new anyway...Maybe I dont need to trade after all

G Bob wrote:

ok...thats the only part I could see that I thougth would tighten it up. By the time I get this thing back together its gonna be like new anyway...Maybe I dont need to trade after all

(famous last words)

ZERO friction lube will still NOT be as nice as power steering!!!

Lee did you have to remove the airbox to get at the bolts for that clamp? I was looking at it this evening. I didnt try the nuts on the frame but they looked welded to me.

I hate when my nuts get welded.

TW you need this

Or maybe a shot of this

No I didn't Bob. I removed the left piece of plastic (opposite the one with the shift lever). The bolts have those fold over locks on them. I will admit they were a bit of a biotch but still easier than changing that back spark plug! The nuts are fixed in position but the bolts will come out. You will end up sliding it out with the bolts still through the clamps.

yeah it wasnt easy..I went ahead and took the breather pipe out to give me a little more room on that side. But managed to get it out. Open my box from Bike bandit and guess what...only one clamp. Invoice says two...bag says two..but only one in the bag. I think its just ordained that I never ride again LOL

There is a lot negativity in the Force right now. I have felt it myself. As the full moon wanes, all Jedi powers should come back to their previous level.

Lee wrote:

There is a lot negativity in the Force right now. I have felt it myself. As the full moon wanes, all Jedi powers should come back to their previous level.

wacker wrote:

Lee wrote:

There is a lot negativity in the Force right now. I have felt it myself. As the full moon wanes, all Jedi powers should come back to their previous level.

1. Lee I am definitely not laughing at you I am laughing with you!!!