EXHAUST EXTENSION FOR 1150GS STOCK EXHAUST

[Lee Frost]

Hi Chaps,

I've just bought a set of Zega 41ltr panniers off a fellow tosser for my 1150 GS which is fitted with a stock exhaust, only to discover than not only is the exhaust extension for a Remus can but the cutout for the exhaust seems to be for a Remus rather than stock end can. Apparently, and correct me if I'm wrong, Touratech used to make Zega panniers with a squared-off cutout for a Remus can and a curved cutout for a stock BMW can. Mine has a squared-off cutout.

I could just buy a Remus end can and solve the problem, but don't want to go to the expense if I can help it.

I could go down the stubby route but don't fancy that either.

So, advice please!

There is a gap between the end can and the pannier that's wide enough to get my fingers in and some heatshield has been fitted by the original owner to the outside of the pannier cutout so I'm hoping the pannier won't get too hot. What do you think? What kind of gap is there between a Remus and pannier?

As for the exhaust extension, the one I have (for a Remus) will fit but it doesn't sit snugly against the end cap of the stock can. I'm wondering if I could adapt it (with a hacksaw!) so it sat against the end cap without any big gaps and maybe put some heatshield around the edge as well to seal any gaps so there's minimal leakage at the join.

Do you reckon this would work?
Anyone had similar problems and overcome them?
The panniers will be off the bike more than they're on but when they are on it'll be for long rides and I don't want to find that my pannier bag welds itself to the pannier side because of the heat!

 

[Teamin]

Try Vern, he may have something.

 

[Bryn]

Don't discount the stubby route... works a treat and saves around 10kg in weight.... no noisier either, the silencing from the cat does it all

 

[MikeP]

Apparently, and correct me if I'm wrong, Touratech used to make Zega panniers with a squared-off cutout for a Remus can and a curved cutout for a stock BMW can.

You are correct, the 'Special set' has different cut-outs depending on OE exhaust or not and the extension is a tube for the OE exhaust that goes inside the end cap (whereas the rectangular extension for the Remus fits over the stubby end-tube).

There is a gap between the end can and the pannier that's wide enough to get my fingers in and some heatshield has been fitted by the original owner to the outside of the pannier cutout so I'm hoping the pannier won't get too hot. What do you think? What kind of gap is there between a Remus and pannier?

The important thing is to ensure that the hot gases are carried beyond the pannier. If not, the rear most plastic mounting pucks are likely to melt (and sometimes the indicator too).

Why not see if TT will supply just the extension pipe for the standard end-can?

You may find that the joint between the exhaust and the extension isn't so critical that it needs to be sealed. You just need to get the worst of the hot exhaust beyond the pannier and indicator (my Special set exhaust extension tube has been in place for seven years, it's never been a tight fit and it's never caused any problems re pannier temperature).

 

[Lee Frost]

Thanks MikeP. I'm going to call TT tomorrow, plus I've dropped Vern a PM and another Tosser may have the pipe I need. One concern is that it also seems the cutout in my pannier, which is squared off, was for the Remus can and not the OEM can, so the end of the pipe in the OEM can is recessed slightly in the cutout which means any extension pipe will need an offset in it of maybe 1/2-1in to clear the cutout. Is your extender offset?

 

[MikeP]

Yes. There's a kink in the pipe, about half an inch as you suggest.

 

[Lee Frost]

Fingers crossed for an easy solution! Maybe it would have been
easier to stick with Hepco & Becker. Too late now though - they're sold!

 

[MikeP]

Persevere. I've never seen anything in the past seven years that I'd swap my Zegas for. In terms of capacity, weight and practicality, there's nothing better.

 

[illustratedman]

extension

tt will supply the part but it aint cheap, silly money for a small piece of pipe. Close to £50ish if i recall right. explored other options last year after mine snapped at the weld where it attaches to the frame and fell of on the m-way, but ended up buying it in the end as i couldnt find anyone local to make one.

 

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