2ltr Aircooled silencer removel/fitting

[martin t25]

hello any tips on removel of silencer ive ground the 2 bottom studs off as they were rounded off
its the top ones ime struggling with now
also when fitting the new one do i have to undo the heat exchangers? from the heads and pods
any help will be greatly appreciated

[Rockhead_Rumple]

If you've had to ground the bottom ones off, odds on the top ones are equally as worse. Unfortunately its pretty difficult to drop both heat exhangers and silencers as one, due to the weight and the fact that the cylinder head studs are at an angle, meaning you have to move the heat exchangers both sideways and down to get em off.

I ended up dropping engine, removing tinware, and grinding off the top bolt for the silencer. However this is pretty extreme for such a small problem! Perhaps try prying the silencer apart now the bottom bolts are off, and just avoid damaging the heat exchangers.

[neil3965]

I had the same problem, all nuts seized, two of lower studs snapped - I managed to remove the upper nuts by drilling into them from the side and then whacking with a small cold chisel until they split (not enough clearance to get a nut splitter onto them).

You should be able to get the new silencer on without loosening the heat exchanger nuts. However, in order to tighten up the upper nuts - or at least the offside one - you'll need a banana spanner, or improvise by cutting the end off a normal 13mm ring spanner (leave about 40-50mm of shaft) and using another ring spanner over the sawn-off end.

Good luck!

[CovKid]

Or fit the one I did lower down this page. Works for earlier waterboxers and 2ltr Aircooled engines:

https://club8090.co.uk/wiki/Exhausts" onclick="window.open(this.href);return false;

[martin t25]

cheers for that i like the look of the bike can but i managed to get hold of a nos vw box
the gas axe is my next option