How Would You Perform This Operation?

Anyway...

While removing my carbon fiber rear hugger to service my rear shock, a very specific, non-standard, non-Honda washer/spacer fell down and perfectly fell into the space between my catalytic convertor and its welded heat shield.  The spacer is necessary to reattach my hugger to a suspension pivot bolt. I tried to fish it out using dental tools and a strong magnet to no avail.  I also tried to remove the whole exhaust manifold, but stopped when I could not even break loose the bolt holding the cat to the lower frame.  How would you fish this thing out? 

Would I damage the exhaust if I cut a hole in the bottom of the heat shield using a dremmel tool taking care not to cut into the actual cat?  Should I continue to try to remove the whole exhaust to shake out the washer? 

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Maybe an air nozzle can make it defy gravity long enough to pop free.

If not then either remove the exhaust or turn the bike upside down....I would flip a coin on which way to go there.  :cool:

A strong shop vac? Be sure you empty it first.


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I have a selection of these in various sizes.  If you can't see the object, a small handheld mirror can help with its location and orientation.

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An opened clothes hanger or suitable gauge wire can be in bent to wiggle in and under the spacer to lift it out. It will really help if via a mirror you can actually locate where it is, otherwise you are working by feel. Patience is the real key.

small magnet on a string?

Qtip  with a piece of chewed gum on the end  !

a very specific, non-standard, non-Honda washer/spacer fell down and perfectly fell into the space

If you know the washer dimensions, or can figure out what they should be, leave it there and get a new one. :comp13:

a very specific, non-standard, non-Honda washer/spacer fell down and perfectly fell into the space

If you know the washer dimensions, or can figure out what they should be, leave it there and get a new one. :comp13:

+1. What's your time worth?

Take a metal coat hangar and straighten it out. Run the coat hangar slowly across a strong magnet to magnetize it (always draw it slowly and the same direction each time) to the point where you can pick up a washer of similar size. Then insert the end of the coat hangar and fish around a bit. This process worked for me when I dropped a metal clip for a car window inside the quarter panel of a customized 1968 Charger show car that I was fixing for a customer. Clip was not replaceable so I had no choice but to try and fish it out.

a very specific, non-standard, non-Honda washer/spacer fell down and perfectly fell into the space

If you know the washer dimensions, or can figure out what they should be, leave it there and get a new one. :comp13:

i would pick this one. Forget the dead one. Go new.
C

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a very specific, non-standard, non-Honda washer/spacer fell down and perfectly fell into the space

If you know the washer dimensions, or can figure out what they should be, leave it there and get a new one. :comp13:

I would if I could find one.  I need a single washer 7/16" ID and 5/8" OD.  Not even McMaster-Carr has that size.

if they have a 5/8" OD but the inner is too small, drill it larger.....

I *assume* your hugger is a bit like this one:

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The washer you refer too fits inside that bracket hole and is thicker than the bracket itself (or you take 2 washers..)

It goes over the lower bolt of your suspension triangle with a larger washer over it so the bracket is kept in place

And -since the washer is a bit thicker- the bracket/hugger can rotate as the rear rises and falls.

If the washer you can get is only slightly larger, just file the hole on the bracket (or file the washer)

Just popped out and took a piccie...

On redslut, that bracket eventually broke off after a few years, so I riveted a new strip of aluminium and used a handrill to make a hole large enough.

Did not have a drill bit large enough, but by "grating" the hole I got there.

Ain't pretty but held for years now  :beer:

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hhhm  that bolt looks a bit short, but with Loctite it held so far. Mebbee fit a longer one still...

@zoomzoom

I will have to try your magnetic coathanger trick when I get back from my business trip. Thanks.

@Dutchy

Yes, that is the cf hugger I own.  Isn't it pretty?  You are right in understanding which spacer was lost.  Although, I did not have that second bigger washer that sandwiched the lost spacer.  It would be possible to make my own if only I owned a bench vise to hold the washer so I could drill it.  If my fishing expedition does not work then I may have to do just that.

Not even gonna try the Qtip with gum, it works.

20 bucks or so

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I no longer had the "inside" washer amd the ones I did have were a bit smaller. So I put the larger one on top to keep them "in"

I messed about with mine, trying to cut out a section in the vertical bit....   Well..... that didnot fare well.

So I married her with a metal chain guard....

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