Help/Tips on Exhaust Replacement

[jgalle]

I should get my exhaust in by monday, and I am going to install it on my 82 XJ1100, so I can ride my bike again. (Previous exhaust fell off, Literally)

I will have to take off the headers also (everything form the engine down) The Exhaust was welded to the headers on the left side only. Just so happens, that was the side braised, and that broke off while riding down the rode. (Previous owner seems to not have cared for this bike) I managed to find some stock Headers and Pipes on eBay recently. Came off of a parts bike, same year, model, and even color.

Do I need to purchase some gaskets or anything? I don't want to mess anything up.

[sixtysix]

I would go ahead and get the exhaust gaskets, they are only about $2 each and you need 4 of them, they crush when the exhaust it installed, so reuse is not recommended. Make sure you pry the old ones out before you put the new ones in.

[tsears]

after the install

Hi,

After you install the new exhaust and run the bike for a hundred miles or so, make sure to retighten all of the header bolts (and check them periodically from then on). This is from a guy who now has three of the four head pipes from a Jardine 4:1 (the fourth got run over!). Yes, I had to buy a whole new exhaust!

Tim

[jgalle]

I need some pictures, etc. I do not know if I have the stock oil cooler or not.

MAC is not being very helpful. Anybody got a picture of their oil cooler. I need to look and see if mine has one. I am not that mechanically inclined, I would have the guy that is writing a claim on my bike check, but they are not open today. I want to get an idea, so I can get this people to ship my exhaust... This is really irritating. I just want to ride my bike...

MAC wrote me in writing. "The 504-0301 4-1 Black MAC Exhaust fits the XJ1100 with oil cooler. The 4-2 does not." So I ordered the 4-1. When I call to double-check, the guy says it does not. Now my exhaust finally arrived in the store, they are about to ship, and I am going nuts...

Any Help will be gratly Appreciated!

[Robert Haller]

Re: after the install

Originally posted by tsears
... make sure to retighten all of the header bolts (and check them periodically from then on).

Good advice. I had both header nuts come off a header during a ride in the mountains. Fortunately it was a stock system so the header pipe didn't fall off. I was wondering what that rattling was (the flange at the bottom of the header). I had to steal a nut from another header to put it back on.

[Rick Wood]

Mac 4-2 On and Looking Good

[nashville_bill]

Great looking bike, but where is the T-KAT fork brace?

[jgalle]

Appreciate the help.
Great Looking bike. Exhaust fits nicely.
I found out my bike does not have an oil cooler.
However, the repairs are really high, Imagine That, and they may total my bike. I am going to try and work a deal, and get it for a little bit of nothing.
Wish me luck as I try to salvage my bike...

sob sob

[Jerry]

Only the '81H XS11 had a stock oil cooler from Yamaha.

In addition to the head to pipe gaskets, the stock XJ system uses 3 other gaskets as well: one where each muffler connects to the head pipes and another where the stock crossover tubes (tube between mufflers) join. The 3 muffler-crossover gaskets are all the same stock number, and the header gaskets (4) are all another stock number. If you reuse the old muffler gaskets they may leak and get your feet really warm, as the unions are just under the footpegs, plus the system will be a bit nosier and you will get some black carbon soot collecting around the muffler to header union.

The muffler gaskets are less expensive than the header gaskets. Replace the headers, at least, as leaking seals can lead to what looks like carburator problems, including backfiring. Trust me, I know.....

Hope you can get it running OK, as the world need more XJs in it.

[strom]

Originally posted by Jerry
Only the '81H XS11 had a stock oil cooler from Yamaha.

Now I'm confused... what's on my 78 1100?

LP

[Jerry]

Stock oil cooler consists of an adapter plate between the oil sump and filter housing. Has 2 lines comming out of it. Stock '81H had a couple tabs welded to frame downtubes to secure hoses from hitting head pipes. Cooler itself was mounted just below steering head (tripple-T) in factory bolt holes. Cooler shroud was in black, or a limited number in chrome.

Several folks have adapted the '81H cooler to other bikes, or there were several after-market units available. If you have a cooler on your '78, I am pretty sure it is an aftermarket or swapped-in unit from an '81.

Oil cooler makes fitting aftermarket exhaust systems a bit more difficult, as the oil filter hangs about 1/2 - 3/4 inch lower on the bike. In addition, at least one member had a line break (they are now 20+ years old) and recommends replacing the old lines with new ones.

Seems to me Gary Granger came across a spin-on filter adapter that would work with the XS-XJ, but I don't have details handy here at work. My recollection is that the filter hung even lower with this adapter, but its been a while since the discussion. Would make filter changes easier, and used a more common filter as well. Other concern was the filter might be punctured by road debris, as it would be more exposed beneath the engine. What we need is a remote spin on filter adapter.....

[Mike Hart]

I'm not positive here, but I think some non-US XS's came with factory oil coolers.

[davidenorth]

Exhaust gasket replacement

I am making all necessary repairs on my 81 XS11sh and I am confused by exhaust rattle on number three pipe. I know I need to replace the gasket but do I have to pull all four headers and replace them or just the offending rattle? I am going to buy four gaskets just for insurance.

[strom]

Gotta take em all off. Replace all four since they're not too expencive.
Gaskets that is.
EU elevens had oil coolers. Mine does.

Will post the pics of my home-made exhaust system ASAP.

LP