Problems installing Left Muffler

[fxrstew]

Following the rear wheel removal procedure, I just installed a new rear tire on my 1993 GL1500. Currently I am re-assembling, but having issues with the left muffler bracket hole not aligning with the bolt to fasten the muffler in place (slide #64). I have tried removing the muffler to clean out the muffler connection, but the bracket hole is still approx 3/8 inch off alignment. Any ideas on how fix this problem.

[WingsandThings]

So the muffler hole is 3/8" back of the hanger hole?

I just put a muffler I got off of ebay on the right side of my 93 today.

It was a chore to get it installed because when they took it off the other bike they couldnt get it off of the collector so they cut it off with a torch. When i got it the outlet from the collector was still inserted in the muffler inlet. I had a really hard time getting it out and in the process the muffler inlet ended up being rather out of round.
I finally got it back into an almost circular shape and used the gasket from my old muffler that was new last year.

When I tried to install the muffler I ran into pretty much the same problem you are experiencing.

I had it on and off a few times but could not get it all the way into the collector.
I ended up putting some lube on the collector outlet and inside the muffler gasket(I used high heat brake silicone lube, ordinary grease may work too)
I got the muffler on as far as it would go and then worked the end up and down and side to side, not to much force though.
Then I twisted the muffler and pushed ahead at the same time. I had to repeat the process 3 or four times but the muffler eventually went all the way on. It was very tight and I had to use a strap wrench to twist it into the proper position.

I don't know if there is any reason that grease or lube should not be used but I didn't know what else to do. Others may have advise on wether or not it should be used but it worked for me.

[offcenter]

Every time I remove my mufflers, I always have trouble getting the right one to go on far enough.
I lube the mufflers with anti-seize lubricant. Then I use a rubber mallet on the tail end of the muffler to drive it on.
If it came off of the bike, it should go back on....or so you would think.

[fxrstew]

In hopes of having less obstruction, I tried a new exhaust gasket and even lubricated it with grease. But,it still will not go far enough to line up the bracket bolt. I was pushing so hard that it pushed the bike off the stand and over to its side. However, the muffler will fit without an exhaust gasket. Maybe it can run without a gasket.

[WingsandThings]

Are you putting the gasket into the muffler and then putting the muffler onto the collector box or putting the gasket on the collector box first and then installing the muffler?

Whichever way you are trying it, have you tried doing it the other way?

[fxrstew]

Good news/Bad news. Good news-I finally got the muffler all the way on and the bike together. Bad news-While test riding, I got rear ended at a stop light. I'm guessing the insurance will want to total the old bile. Fortunately, walked away with just a few scratches.

[WingsandThings]

Sorry to hear that but glad you are ok.

[Rambozo]

Using a car to drive the muffler all the way on, is not the ideal solution.

[WingsandThings]

Using a car to drive the muffler all the way on, is not the ideal solution.

Lol, that thought crossed my mind too