GL1100 exhaust on a GL1200


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cafegoldwang
Posts: 2
Joined: Thu Jul 19, 2018 6:48 pm
Location: Atlanta, GA
Motorcycle: 1986 GL1200 Interstate

GL1100 exhaust on a GL1200

Post by cafegoldwang » Thu Jul 19, 2018 6:57 pm



So I'm turning a busted 86 GL1200I into a cafe racer. The fairings and everything were already gone when I bought it, and the exhaust had been removed. I painted the exhaust, and went to install it tonight, and realized that it's from a 1100, not a 1200. There's about a 3 inch gap in between the cross pieces. I don't want to buy an exhaust on ebay, so do I have any other options? I could cut the cross pieces off either side, and weld on patches, or make an extension piece. I want to avoid screwing around with the carbs too much as well, this project's on the cheap. I saw something about using harley mufflers, does anyone have experience with that?



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eklimek
Posts: 378
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold) 2012 cbr250 gymkhana, 2017 cb500x daily driver

Re: GL1100 exhaust on a GL1200

Post by eklimek » Thu Jul 19, 2018 7:03 pm

I used the harley mufflers on a 81 gl1100. No apparent running issues. The motor is approximately the same displacement.

HD were a bit loud. I could swear they sounded different left to right. Is that HD copyright?

Ed

cafegoldwang
Posts: 2
Joined: Thu Jul 19, 2018 6:48 pm
Location: Atlanta, GA
Motorcycle: 1986 GL1200 Interstate

Re: GL1100 exhaust on a GL1200

Post by cafegoldwang » Thu Jul 19, 2018 7:06 pm

How'd you do it, I can't find specific info on here. Which model mufflers? Did you have to modify the existing exhaust?

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ekvh
Posts: 324
Joined: Thu Apr 29, 2010 9:52 am
Location: Grand Forks, ND
Motorcycle: 1977 gl1000

Re: GL1100 exhaust on a GL1200

Post by ekvh » Thu Jul 19, 2018 10:04 pm

You want to avoid the newer CAT Converter pipes. Older Sportster muffs fit nice, but some Sportsters used different length muffs. Most people would notice if you use a longer connector on the short side.

I bought some Road Kings but they were too long for my tastes. With bags they’re not bad.

I weld mine on solid, but with and adapter good clamps will work.

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eklimek
Posts: 378
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold) 2012 cbr250 gymkhana, 2017 cb500x daily driver

Re: GL1100 exhaust on a GL1200

Post by eklimek » Fri Jul 20, 2018 6:56 am

Two pieces of exhaust pipe (left and right) to offset the header with the muffler was bent for me at a muffler shop. That lines up the header to the muffler position. Can’t remember exactly, but I think I gave him $10 as it came out of the discard pile. The rest is self evident.

Hope this helps.

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eklimek
Posts: 378
Joined: Tue Feb 15, 2011 1:55 pm
Location: St Catharines Ontario Canada
Motorcycle: 81, 82, 83GL1100 in stasis, CB350f x many, (CB400f x2 -sold cb550 -sold) 2012 cbr250 gymkhana, 2017 cb500x daily driver

Re: GL1100 exhaust on a GL1200

Post by eklimek » Fri Jul 20, 2018 7:48 am

Here you go.

All the best.
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brianinpa
Posts: 179
Joined: Thu Mar 25, 2010 7:13 pm
Location: Lebanon, PA
Motorcycle: 1984 GL1200 Standard
1987 GL1200 Interstate

Re: GL1100 exhaust on a GL1200

Post by brianinpa » Mon Jul 23, 2018 8:34 pm

When I turned my 81 1100 into an 81 1200, I used the 1100 exhaust and it fit the 1200 motor in the 1100 frame .

Anyway, if you are using Sportster mufflers, you want 1996 to 2003 as they do not have a crossover tube hole to weld closed.
Brian

If you aren't having fun doing it, find something else to do.

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ekvh
Posts: 324
Joined: Thu Apr 29, 2010 9:52 am
Location: Grand Forks, ND
Motorcycle: 1977 gl1000

Re: GL1100 exhaust on a GL1200

Post by ekvh » Mon Jul 23, 2018 10:16 pm

I took mine to the auto parts store and matched a freeze plug that pressure fit in the cross tube holes. Must be five years now.

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brianinpa
Posts: 179
Joined: Thu Mar 25, 2010 7:13 pm
Location: Lebanon, PA
Motorcycle: 1984 GL1200 Standard
1987 GL1200 Interstate

Re: GL1100 exhaust on a GL1200

Post by brianinpa » Tue Jul 24, 2018 7:56 am

ekvh wrote:
Mon Jul 23, 2018 10:16 pm
I took mine to the auto parts store and matched a freeze plug that pressure fit in the cross tube holes. Must be five years now.
The older years are getting harder to find, but they are out there.


Brian

If you aren't having fun doing it, find something else to do.

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