Join Date: Jul 2018
Location: Central PA
Year/Make/Model: 2009 Kawasaki Vulcan 1700 Nomad
Color: Red & Gold
2009 Nomad - Muffler Mounting Hole Alignment Problem
Hi Folks - I bought 2014 Vaquero stock mufflers from eBay. Before buying, I did some research and concluded that the eBay mufflers should fit my 2009 Nomad. Well, it looks like I was wrong. The right muffler went on with no problem. Unfortunately, the (2) left muffler threaded mounting holes are off by 3/8"., i.e., each muffler threaded mounting hole is 3/8" off of the respective motorcycle frame mount hole it's meant to go through. If the left muffler could be pulled toward the back of the bike 3/8" - all should fit. I've learned that getting the muffler pulled back 3/8" is easier said than done. My attempts to do so result in the left muffler being pulled 80% out of its gasket, which is unacceptable.
The left muffler has the dog-leg pipe that ties into the right-side exhaust. Except for exhaust head bolts, I've loosened just about every bolt that can be loosened to allow me to align the left muffler mounting holes - but no soap. At this point, I'm thinking that the 2014 left-side muffler mounting hole positions differ "by design" compared to the the 2009 models.
One thing I haven't done is loosen the exhaust pipes to heads attachments. There is the potential that this would allow me to finagle 3/8" on the left side muffler but then the exhaust attachments at the motor heads would be off 3/8" . BTW - 3/8" may not seem like much but when it's relative to fixed threaded holes - it is.
Another consideration would be to bend the left muffler's dog-legged pipe, which would be risky and could make matters worse.
Has anyone encountered difficulty aligning the mounting holes on the left muffler of a 1700 and if so, how bad was the misalignment and how did you overcome the problem?
Thanks for your feedback.