Interstate muffler bracket mounting problem

i am installing a set of low level Interstate exhaust pipes and silencers on my basket case Commando. Based on the pictures from an earlier set of posts, I think I have the correct brackets. However, the pipe, muffler combination interferes with the kick start lever operation. Did I assemble the brackets incorrectly? So, do I have the correct pipes? They look like the ones in the parts book (for what that is worth!). Is it so simple as there is a kick start lever specifically for the Interstate model?

Here is a closeup of the right hand side showing the dogleg mounting bracket:


Another view:


This shows the kick start lever with a drastic interference with the exhaust


Another view of the interference:


Left side view. You can see the shape of the pipe:


Left side mounting bracket without the dogleg:


Can anyone post a photo of the right side of their Interstate exhaust? Any help will be appreciated.

Your setup looks similar to the one shown on page 2 of this thread:
commando-interstate-muffler-brackets-t24862-15.html
He is using a later 850 kickstart lever, which has better clearance than the 750 style you are using.
Seems like in your case there is something else going on.

Stephen Hill

The brackets look correct but the brake cable needs to run over the Z-plate, not under, as it is in your photo.
Although the cable is often seen routed incorrectly, running beneath the Z-plate, if it is, it can foul the underside of the plate when the suspension compresses and momentarily apply the brake.



The damper lower mounts should also have the wide 06-7808 wide washers to prevent the dampers from potentially slipping off the rubber mountings.
https://andover-norton.co.uk/en/shop-de ... r-nm22636-

The Subtle Application of Brute Force , may be required for perfect alignment .

One of the few cases working on a motorcycle that a beer may be required . To steady the nerves .

Lumber & perhaps a large malet .

Slight Nip on fittings , Not Tightened untill aligned . Should sit correctly once done , before tightening .

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Strange how multi cylinder headers ( Extractors ) , with a flange per pipe - built / welded ON A HEAD for ALIGNMENT
seldom go on without ' leverage ' applied . After say 1.000 miles - the heat cycles usually have ' hands free ' fitting thereafter .

Not Only That . :twisted:

Used Head O Rings for initial Alignment , so they headers sit in the ' Fin ished ' position ;

Which May Require a long ( A Metre or even 4 Ft. ) piece of say 1 1/4 Galv Pipe up there rear . ( Like Polititions )
to fine tune sit adjacent to frame rails , then suported there , the outlet length .

Straight Edges or a slip in thing ( Even angle alloy or wood , to say adjacent to axle )- to measure off even & equal.

Farting Round with similar debri to check alignment , inlet to can , on the mufflers ; would see if theyre both fine & matched ,
or require massage .

Supporting on soft ( green ) clean pine , spreads the load to avoid mangled & dented overpriced parts .



May be medival but avoid brutality .



Tecnically your FINESSING IT percentages of a degree , not bashing the shit outt of it . Theyre not as thick as those other things these days .

Problem solved. I merely replaced the kick start lever with one "borrowed" from an 850 E-Start project. Thanks for the tip!





My Interpol project as a whole. Now that it is mostly assembled, the tank, side covers and mudguards will be sent off to be painted white:





While I am waiting for the paint to dry (several months, most likely) I will finish up the mechanical bits.

You do not need brute force. I have interstate mufflers on my 750 commando using the standard peashooter muffler bracket set up. Assuming your pipes are standard upswept, I can not tell from the pictures. If upswept headers, then set up the brackets for peashooters. The standard interstate mufflers are a direct bolt in. If you are using interstate headers then you will have to get the interstate brackets, Old Brits may have them. Good Luck, Craig

Upswept headers, like the standard peashooter setup, do not work with panniers. Thee is an interference fit.

Matt Spencer said:

Click to expand...

Those sprocket teeth are guaranteed to outlast the bike's lifetime.

hey commando dave,
I have a late model kickstart that's in excellent condition. ( the elbow type,like the one you swapped from your other project) My issue with it, is that it doesn't work with rear sets, so I had to remove it and put an early "banana shaped" kickstart back in it's place. Are you in the USA? and would you consider a swap of your banana shape kickstarter for my elbow shaped one?

Thanks... let me know