How do I connect muffler and header on my GL1000

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leonardhcross
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How do I connect muffler and header on my GL1000

#1

Post by leonardhcross »

Hello again Goldwing friends. I come asking for guidance as I attempt to mount mufflers on my 1975 GL1000 rebuild project. Here is a video showing my issue. Any guidance would be appreciated. https://www.youtube.com/watch?v=lPJsPjjJ19w&t=3s
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Re: How do I connect muffler and header on my GL1000

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Post by pidjones »

You might have a muffler shop weld new male and female ends on them. They use a 18392-MK5-000 gasket which is a cylinder going between the male and female connections.
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Re: How do I connect muffler and header on my GL1000

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Post by Whiskerfish »

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Re: How do I connect muffler and header on my GL1000

#4

Post by Sandy »

Your muffler is short by about 2". The headers need to insert into a female part of the muffler which you are missing and is part of the muffler. That clamp would then fit around the outside of that part of the muffler. There is also a exhaust gasket material which fits onto the end of the header before being inserted into the muffler then the clamp fits over both pieces. The copper gasket and the other flattened gasket in the exhaust port should squeeze out with a flat screwdriver or wood chisel.
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Re: How do I connect muffler and header on my GL1000

#5

Post by toomanybikes »

We all have different goals, budgets, and approaches, but my first reaction to seeing the video is that I wouldn't trust those rotted out connection points.

If you have some funds and want to go in a different direction, find some headers in better condition and then use HD exhaust mounted directly to the headers with some copper sheet metal acting as the thin gasket. I did this on an '81 GL1100 as shown below.
PXL_20220430_193446423.jpg
PXL_20220430_193446423.jpg (199.65 KiB) Viewed 506 times
and here's the left side with bracket to the passenger peg. Right side bracket is similar
PXL_20220508_180950669.jpg
PXL_20220508_180950669.jpg (171.88 KiB) Viewed 505 times
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Stable as of 26Dec22: '81 GL1100, '10 Bonnie SE, '86 Yamaha Radian, '83 Suzuki GS650L, '14 Moto Guzzi California, '85 Honda V30 Magna
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Lucien Harpress
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Re: How do I connect muffler and header on my GL1000

#6

Post by Lucien Harpress »

And as an added bonus, Harley pipes on a 1000 actually sound really nice. Decent rumble/growl, but not overly loud or obnoxious.
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leonardhcross
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Re: How do I connect muffler and header on my GL1000

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Post by leonardhcross »

Thanks Toomany. Who makes the mounting bracket?
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Jonesz
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Re: How do I connect muffler and header on my GL1000

#8

Post by Jonesz »

leonardhcross wrote: Wed Aug 17, 2022 8:21 am Thanks Toomany. Who makes the mounting bracket?
The easy answer is you or one of your friends makes it. Fairly easy out piece of flat stock once you install the mufflers and get a measurement. I did that for my Gl1000 and GS850. If I can do it you can too. maybe takes a bit of grinding. polishing and a good drill/drill press helps. I agree that the harley sportster takeoffs sound nice. I used pre 2003 mufflers off Ebay. The early ones have no crossover to confuse the mounting etc.
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Re: How do I connect muffler and header on my GL1000

#9

Post by toomanybikes »

leonardhcross wrote: Wed Aug 17, 2022 8:21 am Thanks Toomany. Who makes the mounting bracket?
Jonesz had it right ... I made them myself. You can buy the 1" steel strip from most HW stores, Tractor Supply, etc. The exact style of bracket will depend on which HD pipes you get since their factory mounting varies by model/year.
Greater Boston MA, USA
Stable as of 26Dec22: '81 GL1100, '10 Bonnie SE, '86 Yamaha Radian, '83 Suzuki GS650L, '14 Moto Guzzi California, '85 Honda V30 Magna
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