[arrgh]

Has anyone bolted on a BBR exhaust?

I tried to bolt up a BBR exhaust and the mid bolt did not line up.


As you can see, The mid pipe is off by about 1/2" and no amount of forcing was going to make it happen.

I sent BBR the same photo in an email, I am sure they will work it out.
Being a brand new bike, There are probably a few aftermarket bugs to work out.

I'm just checking to see if anyone else has run into the same issue.

[babykookaburras]

Ugh ....and I just ordered this system from Ken. Hey, Ken, if you're listening, I need you to relocate that mounting hole for me before you ship it....lol Just kidding. Sorry to hear about yours, arrgh. If I do run into the same thing when I get mine and get it on, I'll let you know. Thanks for the heads up, though!

Nancy

[ScottX]

I had the same problem I used a die grinder to oblong the hole and I also had to cut 5/16 off the the mounting bung and cut down the mounting bolt to move the pipe away from the shock spring.

I installed a BBR shock spring and it's larger in diameter than the stock one and the BBR pipe was rubbing it.

Scott

[arrgh]

I contacted Bret or Brent at BBR, I emailed the photo to BBR and Bret, or Brent called me back interested in my problem, They have a couple of 150R's at he BBR factory with the exhaust system installed and cannot understand the problem due to all Honda 150R pipes being made from the same jig.

We went over my installation procedure... He asked me if I tightened everything as I installed, I said no, ( TIP: Always install entire exhaust system loosely before torquing any bolts down )
Ask me, If I installed it "Front to back" or "Back to front"
I told him "front to back" (manifold to exhaust can) and I didn't try "Back to front".

The exhaust can and midpipe install as one piece, (hand tight only) The 2 bolt holes for the hanger bracket on the can and a mount welded on the mid pipe should line up,
Then install the header section and line up as you go along.

I don't know if this will make a difference but its worth a shot.

Only problem is, I keep my 150rb a 100 miles away

I will not get a chance to try to install again for 2 weeks.

Ugh ....and I just ordered this system from Ken. Hey, Ken, if you're listening, I need you to relocate that mounting hole for me before you ship it....lol Just kidding. Sorry to hear about yours, arrgh. If I do run into the same thing when I get mine and get it on, I'll let you know. Thanks for the heads up, though!

Let me know how it works for you Nancy.

Thanks,
Rick

Final tip: When changing those pretty red baffel tips out, stick the plastic handle of a screwdriver in against the baffel and bang the pointed end of the screwdriver down on a bench or floor so it knocks out the tight fitting baffel without marring the red anodized finish.

[babykookaburras]

Thanks so very much for the info! I hope to be getting the system by Sat., but whenever I get to install it, I'll let you know my verdict.....lol.

Nancy

[arrgh]

I had the same problem I used a die grinder to oblong the hole and I also had to cut 5/16 off the the mounting bung and cut down the mounting bolt to move the pipe away from the shock spring.

Thanks for the info Scott,
When I called BBR, They couldn't see how it could be so far off.

I'm glad you validated my problem, I would have used a die grinder If the hole was not so far off,

I'm going to give it another shot for fitment just to confirm.

I will be ordering the spring also, Thanks for the heads up on the rubbing situation.

[babykookaburras]

Scott, glad to know ahead of time that there was some rubbing of the BBR shock spring because I have that coming, too, and will have to deal with that issue when/if it raises it's ugly head. I usually do all of the work myself when it comes to my bikes, but I may just have the shop do it this time.

Nancy

[ScottX]

If you open the forward hole upward about 1/4 inch then the rear hanger will still be misaligned but you can lift it in to place and install the rear bolt.

I will also contact BBR and let them know so they can fix the problem.

Scott

[arrgh]

I will also contact BBR and let them know so they can fix the problem

Scott,
I sent them an email and they never checked until I called 2 days later.
It would be best if you called them at 1-888-668-6227 west coast time.

Ask for Brett, I discussed the situation in depth, You have the added problem of the heavy spring rubbing.

They are easy guys to talk to, and are hungry for input.

I was told they have sent out dozens of pipes for these bikes and I was the only complaint.

[arrgh]

I just got an email From BBR asking how the install went.

I won't get to try the install again until this coming weekend.

I was on a diffrent forum and discussed the problem I had with the install and a few people had the same issue, I got them to contact BBR about their install.

Now they are very interested

I will be taking better more detailed pictures this time... Wish me luck.
I don't think I should have to modify my frame for an exhaust.

Will be updating on Monday.

Rick

[arrgh]

UPDATE

I finally got the pipe installed today, Had to use the mid pipe bolt as a pivot, Then, Install header, Finally, Lift hard on the exhaust can to install the hanger bolt.

I also used the White brothers jet kit.

I was hesitant to install the 130 main jet in the WB kit, I figured it had to be a mistake, 135 is stock!!! So, Thinking...
"I'm smarter than a large company with a trained team and a dyno testing facility"...

I changed the WB recommended jetting to...
45 pilot-138 main.
45 pilot-140 main.
42 pilot-138 main.
42 pilot-140 main.
I tried all these combos along with the WB AP Diaphram, Safety wire mod and leak Jet.
I tried every combo I had (except recommended) without messing with the needle clip.

Today I thought... What the heck, I'll try WB kit as it is suppose to be, With the supplied leak jet (whatever # it is}, 45 pilot and 130 main... Just for grins.

Along with the BBR R/T full exhaust, The WB jet kit, (130 main) 2 turns out... By far, The best setup to date.

It starts very easy, Cold or hot, No bog!

Its like riding a 2 stroke with a full power band.

Had a very good day.

[boxbuilder]

I am going to try the 130 this summer.I might as well i paid $100 for the kit might as well try it.I agree that it sounds lean but i am going to try it.