Suzuki 2 Strokes

The guy that drew this fiche had too much Saki at lunch. It is horribly out of proportion and I think out of order. I'm tired of trying to figure this out and you're tired of hearing about it. It just doesn't make any sense. Let me start with spacer #29. It is way out of proportion It is only 3/16 wide.
Now I thought the outer / upper pipe mounted on the outside of the frame bushing and the inner/ lower pipe mounted on the inside of the frame bushing. I just found out that's impossible as the bracket on the outer pipe won't clear the rear foot peg. So now I'm thinking they must both on the inside. The only thing that would on the outside is #14, 15 and 16. So the muffler brackets are sandwiched together. Number 28 is the nut. It's drawn as though #27 and #29 are out in the middle of nowhere and doing nothing, so they must go between the pipe mounts. Actually I think # 27 goes between the brackets and #29 is last in the stack. I say that because one of the spacers (#29) was stuck to nut and one was stuck ti and inner muffler mount. Am I getting warm?

27 is I think a triangular bit of rubber that is just insulation I think - maybe vibration dampening. I don't know if mine is "right" but afaicr it was just a bolt through the frame mount and nested pipe hangers with a acorn nut and lock washer. I started my bolt on the swingarm side - clearance is limited getting it in that way but it is a thin bolt head and minimizes the chances of the swingarm scraping on it. It also leaves a nice looking nut on the outside.

Yes. 27 is a triangular piece made out of 1mm steel with a rubber pad adhered to one side.

Judging by the marks on the metal, this part was against the outer pipe bracket. On the flip side, the hole in the rubber is larger than the hole in the metal. The spacer fits the hole in the rubber perfectly. This is telling me something, but I'm not sure what. The rubber is in terrible condition but it;s gonna have to do.

I do not have the thick washer part on my bike but I guess I should, only the triangle bits. The entire thing (on my bike) fits between the two exhaust hangers to space them apart - it is he right shape and that is where it was the first time I took it apart. Those round bits look a lot thicker in the fiche - I had first assumed they were bushings in the frame - guess not.

Got it! After looking at the old marks on the parts I was able to determine exactly how it goes together. The real giveaway was when I realized that to OD of the spacer #6 fits the hole in the inner muffler bracket #7. Then I spent much time in MS Paint to modify the fiche by removing all the confusion and numbering the parts in order of installation. I don't know why it confused me so long as it is really quite simple.
So 1, 2 ad 3 go through the frame bushing from the outside. Then on the inside you start with #4. I will definitely hang on to this and you may want to copy it too. The left pair is a mirror image

See my post under "Hanging Nufflers" dated Feb. 14th.

Coyote wrote:So 1, 2 ad 3 go through the frame bushing from the outside. Then on the inside you start with #4.[/img][/url]

Make sure you have swingarm clearance with that orientation. Compress the shocks and make sure before sitting/riding - there is not much clearance. On my bike the nuts will hit the swingarm if they are on the inside.

I've been noticing there's not a lot of room there. I might remove the shocks and pull the swingarm up out of the way and run the bolts from the inside like you did. I am certain that both mufflers hang on the inside, There is no other way. Then I watched some 550 videos to confirm that fact.

That's how it looks in the FSM on Ian's site. Both on the inside.

I might remove the shocks and pull the swingarm up out of the way and run the bolts from the inside like you did.

On second thought, the swing arm pivot is too close to raise it very much with the wheel on. There should be ample room when the bike is on the center stand. The bike is still on the maintenance stand. It is impossible to mount the pipes on the maintenance stand. The bike will be coming off that stand very soon.
I'm keeping my fingers crossed on the pipe internals. I haven't heard any serious rattles while moving them about and polishing, but I've already patched one big rust hole. Not real promising

Chris, FYI, I dug out a repro hard copy of a GT550 parts list and in that, the spacer looks more like real life and less like a tube.