Muffler slipped out of Chrome main tube - how is it attached?

[Troll]

Ok, then. I do have a spare one, if you need it...might be a little expensive to get to you, though

[drifter-paul]

Troll,

I think you are right. Inner spotwelded to outer, then 'goat bladder'  header welded to chrome outer - a pain to align and get rewelded as per original .

I just drilled and put in two rivets at the weld-end and another one near the fishtail end - better more than less. 

[Troll]

I'll look at my spare one, but I'm thinking it's spot welded together

[drifter-paul]

Hi, this has me puzzled.

Today going around a roundabout, I heard the scrape of metal - unusual as I wasn't leaning much (read that as you will  ). Then it continued when I had straightened up !!

The bare metal internal muffler had slid out of it's chrome sleeve. The 25cm (10") original fishtail chrome piece is till attached to the internal muffler (just scratched up). The whole expelled unit is 75cm (30") long, so the bare metal part is 50cm.

This is the original exhaust used on the 99 & 00 models. There is a strip of crushable gasket material wrapped around the exhaust close to the fishtail chrome end. This makes for a tight fit, but it the only retaining mechanism I can see.

I used a bit of wire thru the small hole in the fishtail tip and attached it to the fender arm, and went to town and back - 10 miles.
Had to wiggle the shit out of it, to get it out when I got home to investigate. As the muffler came loose originally after just a one mile trip, I can't just leave it in trusting to the interference fit of the crushable gasket (the wire fix scratches my paint).

Anyone had one apart - the Parts diagram from Kawasaki has it as a whole unit - no detail there !!

Have torqued the engine mounts to 15 ft lbs as per an earlier enquiry.

Thanks