Problems fitting TSR on Series 2!

[Donnie]

I bloody knew buying a viet pipe would end in misery!

It was this or a Franspeed for the gt186 and after a chat with Richard Taylor I opted for the tsr as he's heard of good results.

However, mines a series 2 and despite the listings stating that they fit series 1 2 and 3 it's blatently obvious that they are designed for the S3.

The exhaust hanger wont even go on the studs with a series 2 sidecasing without grinding which was no real hassle, it fits perfectly on my series 3 sidecasing though.

However, trying to line up the holes on the exhaust to the hanger? Not a chance, it's easily 15mm out, easily! There is no way this is going to fit, it's obvious though that if i had a ts1 / imola, using that stub which is shorter it would line up almost perfectly!

So, for me, that's £180 down the drain eh?

tsr1 by Donnie Canning, on Flickr

tsr2 by Donnie Canning, on Flickr

[dave411]

Make a new bracket or use some packing pieces?

[Donnie]

I have neither the inclination nor the facilities to make a new bracket, to be fair i also don't believe that paying the thick end of £200 should result in a product thats not fit for purpose.

I've stripped everything right back including the stub and taken some measurements and the issue is less down to the hangar and more to do with the angle coming off of the stub. As I say, if the shorter ts1 stub is used it would work, but it's the wrong one, i have to use the supplied standard type stub. The issue there is that this stub is approximately 18-20 mm longer. This in turn pushes the whole exhaust off at a greater angle which in turn is causing the problem with the hanger.

Even further, due to this extra angle, i've also measured up the rear tailcan mount? guess what? that doesn't line up properly either

Basically, the proper fix is in the "u bend" between the stub and main exhaust ie the L shape part that joins them both and fastens using the springs, the one made is fine for the ts1 but not the standard stub, if the extra stub length was taken into account then a different L shape middle would solve this easily.

[Adam_Winstone]

Donnie, what a shame! I share your frustration

[Toddy]

Donnie, PM Bamrattle on her ( Trev ) he has the tsr fitted on a series 1 the only issue he had I believe was the end can being close to the panel , might be worth a try

[Donnie]

Sooo annoying, I really took a punt on this exhaust and was certainly impressed out of the box with how heavy and sturdy it seemed plus the extra bracketry etc, I was really surprised given it's from vietnam.

Alas, in the end it turns out it's just another cheap exhaust that requires bodging to try and make it fit.
If it was a case of simply filing a few slots etc I'd live with it but this is too much too far

[Donnie]

Donnie, PM Bamrattle on her ( Trev ) he has the tsr fitted on a series 1 the only issue he had I believe was the end can being close to the panel , might be worth a try

Will do, cheers mate.

[bolzenanker]

Hi Donnie

I feel your pain having had plenty of issues with plenty of parts. However the TSR EVO fitted on my Series 2 real easy, just bolted it on. Only issue was when putting the footboard back on I had to make a crude slot.

Just for reference here's a couple of pics of the standard stub from mine, and the cutout I did just in case they are different from yours.

Standard stub



Fitted to pipe



Slot for clearance



When fitted



My only issue...ground clearance, we have speed bumps at work and I kept clonking it on them.

[Donnie]

stubs the same, I dont even have the footboard on at the moment so not a bother if i have to cut even more off than is already off (having had a jl3 some years back)

I just don't get it then, I've been back and forth all evening looking at it from every angle and don't get why it wont go on

I actually have another engine and I might actually just try and dry fit it on that to make sure im not doing something absolutely bleedin stupid.

[Toddy]

I know this doesn't help but to be honest I have seen them fitted to quite a few series 1's and 2's

[rossclark]

Does it make any difference which way round the stub is fitted?

[MickYork]

are you using a packer on the barrel ?

[Donnie]

Youre right Toddy it doesn't

Ive tried the stub both ways so not that, and no packer.

The issue is basically due to the fact the exhaust downpipes pushs down more than if the ts1 stub was used. If that was in place it would line up perfectly, ive checked

Basically if the hanger slots were 5mm more to the front of the scooter and the front one was about 10mm longer I'd be sorted

[Donnie]

Im getting to a point now where I might just source some sheet steel and make one like Dave411 suggested earlier on even though im loath to do so, but I have a pillar drill, dremel and an angle grinder, it's not gotta be pretty, just has to fit!

Found this http://www.ebay.co.uk/itm/169mm-x-4mm-R ... SwLN5Wkru4 which would be big enough to make a bracket, don't want to use stainless as it would be harder to work with but Id worry about it cracking.

[Wack]

The last TSR I fitted came with 2 hanger brackets with the slots in different positions, but with a little bit of grinding around the chaincase holes I'm sure you could make it sit lower. I've also altered them on the stub and pipe by cutting around 5 mm off both so the pipe sits higher but watch the crossmember clearance. The worst one I fitted was with a chaincase packer which needed 6 mm off the header to allow the chamber to move over more. For the price I think they're a well built pipe with good performance, even JL's need a fettle now and again. Also try contacting TSR as their service is very helpful.

[NorthernJordan]

I assume one was for the standard stub manifold? And did it 'hang' lower than the the other one?
I've recently bought a pipedesign exhaust and the quality is superb... However it only came with a TS1 stub.. Marco kindly posted me another... Inbetween then, id used an old stub but the fit was a little sloppy... So since trying it with the proper stub I cant get it to line up on the chaincase bracket. Exactly as shown above...

Could someone post a picture if the TSR brackets?

[Dave67]

The last TSR I fitted came with 2 hanger brackets with the slots in different positions. Also I've altered them on the stub and pipe by cutting around 5 mm off both so the pipe sits higher but watch the crossmember clearance. The worst one I fitted was with a chaincase packer which needed 6 mm off the header to allow the chamber to move over more. For the price I think they're a well built pipe with good performance, even JL's need a fettle now and again. Also try contacting TSR as their service is very helpful.

Ive just fitted my TSR pipe (2nd one)to my GP and to be honest it was a pain in the ass to line up. I found that by using copper slip inside the pipe joints i could maneuver the elbow around enough to help align the pipe to the casing bracket.
i also had two brackets with the pipe but as this was my second pipe i just used the bracket that was still on the bike.

[Wack]

They're a tight fit on the joints, good for sealing but as said a pig to get on and off. I did one that welded it's self together but an emery flap wheel sorted it.

[Donnie]

yep, two brackets and they both hang the same other than the slots being 5mm farther forward on one than the other, but they dont go down far enough.

Ive already ground a bit round the stud holes and it's made a little difference but nowhere near enough. Im not going to try and force it as thats what snaps exhausts being under tension.

[Donnie]

Oh and already contacted tsr but apparantly out of the 240 of them on the road and them being on their 4th production run, Im the first to ever want to return one for non fitment??