Ural (Ural (УралУрал) ) -- Dnepr (Dnepr (ДнепрДнепр))Mufflers for Russian Motorcycles Mufflers for Russian Motorcycles
with Sidecars with Sidecars Part III: Installation ofPart III: Installation ofBlack Modtop MufflersBlack Modtop Mufflers
on 2003 Ural Patrolon 2003 Ural Patrol(Also See Part 1: Muffler Introduction, Part 2: Muffler Componen(Also See Part 1: Muffler Introduction, Part 2: Muffler Components, ts,
Part 4: AfterPart 4: After--Market Mufflers, Part 5: Chapter 9 of Bill Glaser's Market Mufflers, Part 5: Chapter 9 of Bill Glaser's "Unofficial" URAL 750cc Motorcycle Service Manual)"Unofficial" URAL 750cc Motorcycle Service Manual)
Ernie FrankeErnie [email protected]@tampabay.rr.com
12 / 201212 / 2012
Modtop Performance Black Mufflers for UralsModtop Performance Black Mufflers for Urals•Modtop Performance LLC–Dan Malinowski–34973 300th St., Henderson, MN 56044–http://www.modtopperformance.com/
• Specializing in Parts for Ural Motorcycles–High-Quality, Retro Muffler Assemblies–American-Made using Quality Steel
and Muffler Bodies with High-Temperature, Durable, Hotrod Black, Powder-Coat•Can Withstand Temperatures Greater than 1,000°F•Coating Will Not Dull or Chalk Like Most Powder Coats
–3” diameter Body, 15 gauge Wall, with 1 ¾” diameter Cores–Inlet/Outlets are 1 ½ diameter, 14 gauge Pipes with Inlet Expanded to Fit Over Stock
Pipes or the Extension Pipes–Includes Custom-Made Large "P" Clamps, Small Clamps, Extension Pipes and Hardware–If Not Satisfied with Fit, Finish or Sound of Mufflers, Return Them for Full Refund–List Price: Muffler Kit with 1 pair of Small Clamps: $224.99
• If 2010 or Newer Model and Do Not Have the Small Hanger Clamps on Exhaust System;–Order the Muffler Kit with 2 pairs of Small Clamps–Muffler Kit with 2 pairs of Small Clamps (for 2010 and newer models): $234.99
• Powder-Coating of Header Pipes and Crossover Pipes Also Available on an Exchange Basis•Note: Modtop Performance Powder-Coat, Transition Pipes Do Not Contain Catalytic Converters
Modtop Performance is proud to offer black powder-coated replacement mufflers for Ural motorcycles, and they’re proud of them.
Transition PipesTransition Pipes
Black, PowderBlack, Powder--Coat MufflersCoat Mufflers
Large PLarge P--ClampsClamps
SmallSmallClampsClamps
Transition / Catalytic Converter (CatCon) Pipes• Transition Pipes Needed to Establish the Correct Angle from the Exhaust Manifold
(Headers) before Entering the Muffler–Transition between Header (“J” Pipe or Exhaust Manifold) and Muffler (Silencer)–About 9” Long for Ural (Part #: IMZ-8.123-12036) for 2003 Patrol
•Ural Transition Pipes Also House a Catalytic Converter at One End: Transition/CatCon Pipe•Modtop Performance Black, Powder-Coat, Transition Pipes Do Not Contain Catalytic
Converters•Options for Using the Modtop Black Transition Pipes during Muffler Replacement–I. Add Black Modtop Transition Pipe to Existing Chrome Ural Transition/CatCon Pipe• Places End of Tailpipe About 11” beyond Rear Axle•Retains Catalytic Converter (CatCon)
–II. Replace Chrome, Ural Transition/CatCon Pipe with Black Modtop Transition (no CatCon) Pipe• Places End of Tailpipe Only 6” beyond Rear Axle• Eliminates Catalytic Converter: Increases Power by a Few HP, Eliminates Converter
Fouling• Legality Problem
–III. Retain Chrome Ural Transition/CatCon Pipe and Don’t Use Black Modtop Transition Pipe• Places End of Tailpipe Slightly Ahead of Rear Axle•Retains Catalytic Converter (CatCon)
–IV. Eliminate Any Transition Pipe•Won’t Work: Body of Muffler Hits Drivers Foot-Peg•Also: Not Possible to Make the Transition without Any Transition Pipe
Transition / Catalytic Converter (CatCon) Pipes
Much of the installation of replacement mufflers involves the transition pipe, as we present the pros and cons of retaining the chrome transition/catcon pipe.
Transition / Catalytic Converter (CatCon) Pipes Transition / Catalytic Converter (CatCon) Pipes (cont.)(cont.)• Is the Original Ural Transition/Cat Pipe Still Needed? Maybe / Maybe Not–Federal Law Prohibits Removal or Replacement of a Properly Functioning OEM (Original
Equipment Manufacturer) Catalytic Converter• If the Vehicle Was Manufactured after 1986, It Must Retain the Catalytic Converter
• Is My Motorcycle Required to Pass a Tailpipe Emissions “Smog-Check?–Depends on the State:• Some States Do Not Have Any Emissions Testing• In Some States, Smog-Checks Required in Populated Areas, But Not in Selected Rural
Areas•With Laws and Regulations Changing at an Increasing Rate, It Is Very Difficult for the
After-Market to Keep Ahead of Changes•Contact Local or State Agencies for Information Regarding Local Emissions Laws• Exceptions Usually Include Vehicles Designed for Off-Road Use Only
–On the Other Side, Motorcycle Owners Run the Risk of Converters Clogging, Which Doesn’t Help Emissions Either• It's No Wonder the Catalytic Converter Is Often Tossed Out in Favor of a “Test Pipe" ( a
straight-thru pipe, no CatCon), Except That It’s Illegal
Legality means that the catalytic converter must remain in the exhaust system, even if it means that the converter may clog or deform
affecting the emissions in an even worse way.
Catalytic Converter (CatCon) Inspection Catalytic Converter (CatCon) Inspection (John Grocke (a.k.a. JohnBG) at www.russianiron.com)(John Grocke (a.k.a. JohnBG) at www.russianiron.com)
• JohnBG Pulled Apart Muffler and Found the CatCon Completely Imploded (shown below)–Caused Abnormal Operation of 750cc Ural
•Construct “Test” Pipes to Show Effect of Clogged Transition Pipe (strictly hypothetically speaking)–Many Riders Have Been Lured to Installing “Test Pipes” for Less Back-Pressure and
Increased Horsepower–Method 1 to Construct Test Pipes without CatCons:•Remove Transition Pipes (on each side, between the J-pipes and the mufflers)•Use Small Grinder, Dremel Tool or Bench Grinder to Grind Away the Welds that Hold
the Converter in Place• Pull Out the Corrugated Web and S-Piece
–Method 2 to Construct Test Pipes without CatCons:•Remove Transition Pipes (on each side, between the J-pipes and the mufflers)•Hack Saw a Little Ring on the Pipe Side of the Weld and Discard the Stub
GoodGood BadBad
Ural placed a small catalytic converter in each transition pipe, between the muffler and header pipe, so the bike could meet U.S. import criteria.
Many Reported Catalytic Converter FailuresMany Reported Catalytic Converter Failures
Interesting!Interesting!
2010 Patrol Catalytic Converter2010 Patrol Catalytic Converter((affordableaffordable--beemersbeemers..smugmugsmugmug.com) www.www.uralural..czcz.com)
2003 Patrol with Ural Chrome Torpedo Muffler2003 Patrol with Ural Chrome Torpedo Muffler
This Ural Patrol is missing the transition/catalytic converter pipes, thus leaving the end of the tailpipe a few inches ahead of the rear axle.
Tailpipe Ahead Tailpipe Ahead of Rear Axleof Rear Axle
2011 Ural Patrol2011 Ural Patrol--TT
End of Tailpipe ExtendsEnd of Tailpipe Extendsabout 6about 6”” beyond Rear Axlebeyond Rear Axle
Chrome, Ural Transition / CatCon PipeChrome, Ural Transition / CatCon Pipe
End of Tailpipe ExtendsEnd of Tailpipe Extendsabout 6about 6”” beyond Rear Axlebeyond Rear Axle
Ural advertisements show the Ural with the transition/catalytic converter pipes, yielding a tailpipe extending about 6” beyond the rear axle.
Ural TailpipesUral Tailpipes
Chrome, Ural Transition / CatCon PipeChrome, Ural Transition / CatCon Pipe
2009 Ural2009 Ural--T Stainless ExhaustT Stainless Exhaust(tailpipe a few inches beyond rear axle)(tailpipe a few inches beyond rear axle)
2011 Ural Patrol2011 Ural Patrol
2011 Ural Patrol2011 Ural Patrol
Chrome, Ural Transition / CatCon PipeChrome, Ural Transition / CatCon Pipe
Typically the tailpipe extends slightly (about 6”) beyond the Ural’s rear axle.
2003 Owners Manual Showing 2003 Owners Manual Showing Transition / Catalytic Converter PipeTransition / Catalytic Converter Pipe
Transition / Catalytic Transition / Catalytic Converter (Converter (CatConCatCon) Pipe) Pipe
(left(left--side)side)
Transition / Catalytic Transition / Catalytic Converter PipeConverter Pipe
(right(right--side)side)
Ural Chrome Ural Chrome Torpedo MufflerTorpedo Muffler
(left(left--side)side)
Ural Chrome Ural Chrome Torpedo MufflerTorpedo Muffler
(right(right--side)side)
The transition/catalytic converter (CatCon) pipe was added to the exhaust system to satisfy EPA requirements for imports.
Item # Item # Part # Part # Description Description Qty Qty 1 1 IMZIMZ--8.1238.123--12003 12003 Muffler Assembly Muffler Assembly 222 2 IMZIMZ--8.1238.123--12004 12004 Header Pipe Header Pipe 113 3 IMZIMZ--8.1238.123--12007 12007 Header Pipe Header Pipe 114 4 IMZIMZ--8.1038.103--1210312103--10 10 Clamp LHClamp LH 115 5 IMZIMZ--8.1238.123--12103 12103 Clamp RHClamp RH 1166 6,312,1086,312,108--20 20 Connecting Pipe Connecting Pipe 117 7 IMZIMZ--8.1238.123--12036 12036 Branch Pipe Branch Pipe 228 8 IMZIMZ--8.1018.101--12112 12112 Clamp Clamp 669 9 IMZIMZ--8.1238.123--12114 12114 Clamp Clamp 1110 10 6,612,270 6,612,270 Muffler Nut Muffler Nut 2211 11 IMZIMZ--8.1238.123--12114 12114 Clamp Clamp 1112 12 IMZIMZ--8.1078.107--12060 12060 Clamp Clamp 11
2003 (IMZ2003 (IMZ--8.103) Ural Patrol Exhaust Assembly8.103) Ural Patrol Exhaust Assembly
7. Transition / Catalytic Converter (7. Transition / Catalytic Converter (CatConCatCon) Branch Pipe) Branch Pipe
1. Ural Torpedo Mufflers1. Ural Torpedo Mufflers
2. 2. ““JJ”” Header PipesHeader Pipes
9. Large 9. Large ““PP--ShapedShaped”” Muffler ClampMuffler Clamp
11. And 12. Large 11. And 12. Large ““PP--ShapedShaped”” Muffler ClampsMuffler Clamps
3. 3. ““JJ”” Header PipesHeader Pipes
6. Cross6. Cross--Over PipeOver Pipe
CatCon Section of CatCon Section of Transition PipeTransition Pipe
10. Muffler Nut10. Muffler Nut
4. Header Bracket4. Header Bracket
8. Pipe Clamp8. Pipe Clamp
5. Header Bracket and Pipe Clamp5. Header Bracket and Pipe Clamp
My 2003 Ural Patrol, My 2003 Ural Patrol, beforebefore Adding Black PipesAdding Black Pipes
With the original transition/catalytic converter pipe installed on my 2003 Patrol, the Ural chrome “torpedo” muffler extended about 6” beyond the rear axle.
Transition / Catalytic Converter Pipe Ural Chrome
Torpedo MufflerJ-Header
Pipe(Exhaust Pipe)
66””
CloseClose--Up of the Old Chrome Exhaust System on 2003 PatrolUp of the Old Chrome Exhaust System on 2003 Patrol
Transition / Catalytic Converter Pipe(Transition / CatCon Pipe)
Ural Chrome Torpedo Muffler
J-Header Pipe(Exhaust Manifold)
Muffler Nut
Bracket for J-Pipe Header
The catalytic converter is contained in Ural’s chrome transition pipe in the center.
Modtop Performance Black Mufflers for Ural Motorcycles
Large Large ““PP”” ClampsClamps
Small ClampsSmall Clamps
Extension PipesExtension Pipes
Black PowderBlack Powder--Coated MufflersCoated Mufflers
Step 1: Make sure the pipes will easily fit into each other. Step 1: Make sure the pipes will easily fit into each other. This will save effort to trying to get them to fit, especially This will save effort to trying to get them to fit, especially in the hardin the hard--toto--work work centersectioncentersection between the between the motorcycle and the sidecar.motorcycle and the sidecar.
Tools Required:Tools Required:13 mm, 14 mm, 19 mm Socket Set and Box Wrench13 mm, 14 mm, 19 mm Socket Set and Box WrenchHammerHammerBlock of WoodBlock of Wood
Modtop Performance Black Mufflers for Ural Motorcycles
The Modtop Performance mufflers come with custom-made large "P" clamps, small clamps, extension (transition) pipes and hardware.
Replacing the LeftReplacing the Left--Hand MufflerHand Muffler
Muffler NutMuffler Nut
Chrome PChrome P--ClampClamp
Ural Chrome Torpedo MufflerUral Chrome Torpedo Muffler
Passenger FootPassenger Foot--PegPeg
Chrome PChrome P--ClampClampStep 2: Remove the leftStep 2: Remove the left--hand muffler. This muffler is easier to hand muffler. This muffler is easier to replace and will yield valuable experience before tackling the replace and will yield valuable experience before tackling the right (center) muffler. Loosen the compression joint (muffler right (center) muffler. Loosen the compression joint (muffler nut) at the front of the mufflers with the spanner supplied in nut) at the front of the mufflers with the spanner supplied in the Ural tool kit.
Step 3: Use a 19 mm wrench to remove the rear, leftStep 3: Use a 19 mm wrench to remove the rear, left--hand hand (passenger) foot(passenger) foot--peg (nut & lockpeg (nut & lock--washer) which holds washer) which holds the large chrome the large chrome ““PP”” clamp, supporting the Ural chrome clamp, supporting the Ural chrome torpedo muffler.
the Ural tool kit.torpedo muffler.
Slotted, Round Muffler Nut that Holds Slotted, Round Muffler Nut that Holds the Muffler to the Transition Pipethe Muffler to the Transition Pipe
Passenger FootPassenger Foot--PegPeg
Replacing the LeftReplacing the Left--Hand MufflerHand MufflerChrome PChrome P--ClampClamp
Ural Chrome Transition / CatCon PipeUral Chrome Transition / CatCon Pipe
Catalytic Converter End of the Transition PipeCatalytic Converter End of the Transition PipeStep 4: Using a 14 mm socket and wrench, remove the small Step 4: Using a 14 mm socket and wrench, remove the small clamps at each end of the transition/catalytic converter pipe. clamps at each end of the transition/catalytic converter pipe. Remove the chrome torpedo muffler.Remove the chrome torpedo muffler.
After removing the footAfter removing the foot--peg, the chrome peg, the chrome ““PP--bracketbracket”” is then is then free of the motorcycle frame.free of the motorcycle frame.
Step 6: Install the muffler using the large muffler clamp on Step 6: Install the muffler using the large muffler clamp on the step peg, while rotating the new 9the step peg, while rotating the new 9”” transition pipe. transition pipe. Leave the large Leave the large ““PP--clampclamp”” loose while fitting.
Step 5: Slip the new black transition (9Step 5: Slip the new black transition (9””) pipe tube onto the ) pipe tube onto the old chrome transition/catalytic converter pipe. This new old chrome transition/catalytic converter pipe. This new transition pipe pipe can be rotated to allow the muffler to transition pipe pipe can be rotated to allow the muffler to align properly.align properly. loose while fitting.
Replacing the LeftReplacing the Left--Hand and RightHand and Right--Hand MufflersHand Mufflers
Step 7: Gently rotate the muffler inside the transition pipe to Step 7: Gently rotate the muffler inside the transition pipe to achieve the best fit, always looking to see the angle the achieve the best fit, always looking to see the angle the muffler makes with the frame.
Step 8: After having achieved the right angle, tighten the Step 8: After having achieved the right angle, tighten the small clamp (14 mm ) between the old chrome transition/ small clamp (14 mm ) between the old chrome transition/ catalytic converter pipe and the new black transition pipe catalytic converter pipe and the new black transition pipe (13 mm for new black clamp). Use a block of wood and a (13 mm for new black clamp). Use a block of wood and a hammer (or rubber mallet) to gently tap the end of the new hammer (or rubber mallet) to gently tap the end of the new black transition pipe as far to the left as possible. Then tap black transition pipe as far to the left as possible. Then tap the black Modtop muffler home and tighten the black Pthe black Modtop muffler home and tighten the black P--clamp.
muffler makes with the frame.
clamp.
Alternatively, you may want to leave out the Ural chrome Alternatively, you may want to leave out the Ural chrome transition /transition / CatConCatCon pipe, which will keep the end of the pipe, which will keep the end of the
tailpipe from extending 11tailpipe from extending 11”” beyond the rear axle, or simply beyond the rear axle, or simply delete the black transition pipe and retain the Ural chrome delete the black transition pipe and retain the Ural chrome
transition /transition / CatConCatCon pipeStep 9: Repeat for rightStep 9: Repeat for right--hand (center) muffler.hand (center) muffler. pipe
Modtop Black Muffler Installation Modtop Black Muffler Installation With / Without Ural Chrome Transition/CatCon PipeWith / Without Ural Chrome Transition/CatCon Pipe
Installation Installation withwith Ural Chrome Ural Chrome Transition/CatCon PipeTransition/CatCon Pipe
Installation Installation withoutwithout Ural Chrome Ural Chrome Transition/CatCon PipeTransition/CatCon Pipe
66””
Black PBlack P--ClampClamp
Ural Chrome Transition /Ural Chrome Transition / CatConCatCon PipePipe
1111””
Installation Installation withwith Ural Chrome Ural Chrome Transition/CatCon PipeTransition/CatCon Pipe
1111””
Installation Installation withoutwithout Ural Chrome Ural Chrome Transition/CatCon PipeTransition/CatCon Pipe
Installation of the Modtop Performance mufflers without the chrome Ural transition pipe is much more pleasing, as it doesn’t extend as much beyond the rear axle.
Curing the Modtop Performance PowderCuring the Modtop Performance Powder--Coat ExhaustCoat Exhaust
•Powder-Coating Has Dried, But Needs To Be Fully Cured by the Heat of Exhaust System–Do Not Overheat the Part before It Is Fully Cured–Run the Engine in a Well-Ventilated Area Only–To Cure Coatings on the Motorcycle:•Allow Engine to Idle, or Drive Gently for Approximately 60 Minutes, or Until No Vapor/Smoke Is Given Off by the Coating
•Caution: Excessive Exhaust Heat, Due to a Poorly Tuned Engine Can Damage the coating During the Cure Process–Do Not Install on a New Engine Until All Adjustments Have Been Made to the Valves, Timing and Jetting
Gentle operation or idling for one hour completes the curing process of the powder-coat.