Plea to Convert owner's: Exhaust crossover clearance to ATF line?

[brider]

I'm re-installing the exhaust on my Cal 2 Auto, and I'll be darned if I can rig the whole assembly so that the exhaust crossover does not bang against the TC return-line banjo bolt at the bottom of the clutch case. This banjo bolt obviously does not exist there on other Tonti models. I did not take actual or mental pics of any clearance or relationship in this area when I pulled it all off over a year ago.

I figured it was smart to use the header installation as the baseline position, with the new "rings" nested into the heads, and the header flanges snugged up flush with the finned retainer and (2) nuts/studs per cyl. Snugged, but not yet tightened down. Then with the crossover slid on to where the previous installation position looks like it was, the crossover pipe lies almost directly under, and makes hard contact with, the TC banjo bolt.

I could slide the crossover farther aft to get clearance, but that's a long way and the reduced overlap on the headers is visible looking at the exhaust inboard of the footboards. This might be the only option, but I wondered if any Convert owners could look under their machines to see what relationship THEY have between the crossover pipe and the TC return-line banjo?

[Antietam Classic Cycle]

On my '76 Convert, with used replacement headers and a new aftermarket crossover, I found it necessary to make a "divot" in the crossover for clearance.

[brider]

On my '76 Convert, with used replacement headers and a new aftermarket crossover, I found it necessary to make a "divot" in the crossover for clearance.

That's GOLD, Jerry....er, I mean, Charlie! Did you wonder, like me, how the exhaust without the "divot" was originally rigged? Mine ran for 45k miles in original configuration, just can't replicate that configuration now.

The other problem I'm having is the sidestand making contact with the left muffler before it makes contact with the rubber bumper on the footboard mount, but that's a side-to-side adjustment that I think I can figure out.

[fotoguzzi]

help me remember this right, I thought the TC return line was the lower of these two fittings (just in front of the  red tape) and the bottom of box was just a drain?

[Antietam Classic Cycle]

I did wonder, but wanted to get the thing on the road, so just made the divot and moved on. It seems like either the headpipes need to be slightly longer or the forward legs of the crossover need to be longer.

[brider]

help me remember this right, I thought the TC return line was the lower of these two fittings (just in front of the  red tape) and the bottom of box was just a drain?

OK, a drain is more accurate, but it's still a TC line with a banjo fitting at the very bottom of the clutch case (?) that "returns" to the ATF tank. Take a look.

[chuck peterson]

Try this.....hold my beer.

Flip the fitting. Reroute the hose.

I'm working on 15 yr old memories but I believe instead of going toward the back (hitting the crossover) have it go to the side. Should position in there so nothing rubs.

Unbolt, flip the drain fitting, rotate, reroute the hose.

Hat tip to Father TOMB Bailey....

[Roy gardner]

Its close. What Chuck said, it goes sideways, to the left, see my dirty pic.   
I made a block to move my sidestand out, that's mostly because my stand pivot is seriously worn!
 

[fotoguzzi]

Its close. What Chuck said, it goes sideways, to the left, see my dirty pic.   
I made a block to move my sidestand out, that's mostly because my stand pivot is seriously worn!
 

nice pic..
get a new SS pivot here,
http://www.mgcycle.com/index.php?main_page=product_info&cPath=73&products_id=371

[bigbikerrick]

the one on my 84 Cal II auto, looks the same as pushrodtwin's picture. I barely have clearance to get a socket on the bolt to snug it up. Next time I have the exhaust off the bike, I am going to make a divot in the crossover like charlie did to get a bit more clearance.
Rick.

[Aldo]

I'll try to get a pic when I get home of my setup. It's pretty close, but not touching at all. FWIW, I just recently finished taking the convert apart and put back together again to install the heavy cast flywheel, but everything seem to fit back the way it was initially. On that note, is it possible you swopped the header pipes L for R during process? Dumb question, I know, but I think they're slightly different lengths, which may put your crossover at the wrong spot if installed incorrectly.




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