Problems fitting TSR on Series 2!

[gp200ts1]

Surely there is no difference between a series 2 engine and a series 3 engine? The barrels and cases are the same dimensions so if it fits a series 3 it should be the same fit on a series 2 engine?

[Stevepshipley]

Donnie, i managed to fit mine on a (spanish - any difference?) S2. Had to open the hanger holes on the casing a bit - but hey?. Was a bit tight cant rembember which hanger i used. Had to trim the footboard ( bought a repro rather than cut the original one) only slight problem is it touches the side panel so had to try and protect that a bit. I wouldnt have suggested this exhaust if i thought it was shit.

Would a photo help? Its on a muggy 198 kit.

[Stevepshipley]

Also, i was mildly worried about the "issue" with ground clearance (lots of speed bumps round my house) so i asked my mate in the event of a problem could he shorten the stub. He said he could, but the problem hasnt manifested itself so i didnt bother.

[bazza3004]

Hi donnie. I got 2 chain case brackets with mine . Think they are different from memory. I used the one that fitted my gp so il post you the other to try if thats any use to you. Foc. Baz.

[bazza3004]

Sorry donnie id only just got up and hadnt read all the posts. I now see you have already discussed the other bracket. (Unless im asleep again and dreaming)

[bazza3004]

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.

when I received my TSR I had to do some serious work on the barrel stub with emery cloth to get the L shaped part of u bend to fit over it correctly . As it was it would only fit part way on to the stub.

[Donnie]

cheers all, sorry for not replying sooner, Sunday was the day out with her indoors then 2 mad 12 hour shifts have knackered me

Im going to hang onto the exhaust as I just cant afford to be sending it back then waiting until mid february for the money then probably getting an email charging a restock fee then taking more money off for the fact Ive tried to fit it and its got marks on etc etc etc

So the task today is order some sheet metal and while im waiting for that go over it all yet again to ensure im still not misisng something, it's not like ive not fitted several exhausts to several different engines over the years.

[bolzenanker]

Hope you sort it out. Was just thinking, and please tell me to shut up if this no help at all, but does a little rotation at the second joint help at all?

[Donnie]

tried it
that joint works vertically whereas the stub joint works longitudinally .
so trying to get the holes to line up using the longitudinally and vertical isnt working as there is a third axis that needs to come into play.
Bear with me.

three-axis by Donnie Canning, on Flickr

So, the rotation of the whole exhaust on the stub only is the longitudinal, rotation at the second joint is the vertical. The problem is that there is no actual lateral adjustment and theres the rub.

With the ts1 stub its not required, it sits pretty much correct, but the longer standard stub pushes the exhaust laterally downward to the ground and that affects everything

[Warkton Tornado No.1]

Hi Donnie.

It’s not right that an item you’ve bought doesn’t fit. Unfortunately, I think it’s a problem that has been around for a long, long time, especially with exhausts. The Ancillotti Ø 50 mm exhausts that surfaced in the 70’s & had to be persuaded on….

From the angle of your photos, it looks as though you might be able to use packers initially to take up the gap. M8 isolation mounts, preferably. Failing that, a stack of washers!

I’d be inclined to use something to keep it (not in its proper) place & run it to get it hot & gradually take away the spacers a little @ a time.

I think that gradually, it would sit where you want it to.

If it failed through fracture, your attempts have been recorded here & the supplier would be mad to reject any claim.

[Donnie]

I don't know if people are misunderstanding, if you look at my pics there is a packer on the left hole of the hanger, 2 come with the exhaust, my issue is not a gap where the hanger meets the exhaust, there's supposed to be a gap between them where the packers go not unlike something like this



It's when the packers are fitted that the holes don't line up and it's impossible to get the M8 bolts through.

Ive spent the last hour or so with a dremel and a bench grinder trying to modify the current hanger, the exhaust stub and the exhaust flange and think im getting there.

This is a far flung journey from the usual fettling we expect from parts to be honest.

[bolzenanker]

I did think while typing that I could be barking up the wrong tree.

Good luck with it and let us know how you get on.

[Warkton Tornado No.1]

I did think while typing that I could be barking up the wrong tree.

Good luck with it and let us know how you get on.

That makes two of us!

[dave411]

I am sure you will get there in the end Donnie.I had to cut a tab off my Ancilloti and re weld it on,then drill and tap a hole in the bottom of the crankcase to take the bolt.
It seems a fact of life that most parts are a crap fit,this is my first Lambretta restoration,and this problem doesntseem like its going to go away,only get worse.
Chin up and keep dremeling.

[NorthernJordan]

I don't actually think that it's the difference between the two stubs to be fair. Having a similar issue myself, I was following the same trail of thought. However, if you look at a TS1 barrel the exhaust port is very proud of the barrel, and this is compensated for in the length of the stubs.

[Donnie]

Now THAT is interesting, as I didn't have one to hand I'd not even thought of that!

As it is, i've finally managed to get it to fit, just about. My poor bench grinder, dremel, hand file, pillar drill all have had to come into play and its taken the thick end of 2 days to sort it and ensure it's not actually under any stress anywhere! What a joke.

[joespeed]

do not be tempted to fit the exhaust under tension,it will crack and rip studs out you have been warned,
i have three of these exhausts all on series three models ,there should not be an issue being a series one,
try a polishing spindle in the joints to allow easy fitment if the bracket still doesnt line up then the last resort is the extend the bracket (or make a new one) and yes your right a little old lady couldn't be able to do this but you ride a lambretta sort it!
the tsr exhaust is well made and well engineered giving lots of fitment options the only thing once fitted is to check the brace bracket from the main box to the tailpipe may need grinding off to clear the panel ,

[Donnie]

that whole post is contradictory

[NorthernJordan]

My pipe design exhaust fits very well now I've received another bracket from Marco.
It looks pretty much the same as the TSR ones, and has resolved the issue I was having similar to donnies.