1981 KZ1000 CSR exhaust problem

My bike has a piece of sheet metal, probably from some of the interior baffeling, that is floating around inside the mufler. I can't seem to be able to remove it with needle nose pliers. My question is what happens if I drill out the three rivets that seems to be holding on the back plate of the muffler? Will it come out or is it welded also? Will I be able to get it riveted back in place?

It sometimes will partially block the exhaust and it couldn't be helping anything.

Thanks,
Robert

Saltydog:

I had a terrible rattle in both my exhaust megaphones. I developed a case of the "screaming mimis" after a while. It got to me so badly that I tore into it by heating the rear edge of the megaphone and bent the edge outward. Then had to heat and cut the 3 spot welds loose. After that, the entire baffel can be removed. Mine was coming apart somewhat but I welded it back together and re-installed it, then bent the edge back into position and spot welded the 3 places.

The side I worked on is now functional but looks like a dogs rear end. I haven't done the other side yet. I will either replace the entire system with an upgrade, or smoothly grind off the last 1/2" or so of the megaphone so it will have a smooth edge again and build or buy a custom baffel that won't rattle.

You could definitely get your piece of metal out by doing this, but it ruins the appearance of the rear of the unit. :S

I used to race J/24 sailboats. I suppose you have a story behind your user name.
:laugh:

Bill,
Thanks for the reply. I'd hate to mess up my muffler any more than necessary. I think I'll check with a friend and see if maybe I can cut out the end with a plasma cutter. I'm gonna have to do something.
I live in North Texas on Lake Texoma and do some sailboat racing but my user name comes from my favorite, after beer, adult beverage.
Thanks,
Robert

If I remember correctly from The KZ1000P site , people have basically cut out a square hole from the back side or bottom of the muffler, removed the loose material and them welded the piece cut out or a patch back on the muffler and went on their way.


Maybe you could try that.