opinions on turnout exhaust for XJ

[deo]

I need to put a new exhaust system on my bike and am looking at the Mac turnout system to replace the standard look. Is there anything that I should know before I order it? I don't believe I have an oil cooler so that shouldn't matter. Is there anything else that I need to be aware of. I am looking at putting hard bags on the side, will this effect the way they fit and is the fit the same with the bags and without.

dave

[Jerry]

I don't know much about the MAC system, so will jut make a couple of general notes.

XJ stock system has a cross-over pipe that connects the mufflers. Crossover is just behind the header to muffler connection. Purpose is to help lower range scavenging; if the MAC system does not have this crosover you might loose some lower end performance. Stock mufflers tend to rust at this joint, BTW.

Stock pipes end before the rear axle bolt, making it easier to change tires. (XS models had a special tool in the toolkit to held the wheel up so the bolt would clear the mufflers.) If the MAC pipes are longer than stock you might have a little more work in tire changing.

MAC pipes have a reputation for being louder than stock pipes. Some like it, some don't. I had MACs on a Honda, didn't mind the sound but was more tiring on long trips.

MAC (and most other sytems) header pipes will discolor more easily than stock headers, which are a double-wall construction vs single wall. Don't be surprised if , after some use, the pipes turn blue (sometimes gold) right at the engine.

You shouldn't have a problem with mounting hard bags. The stock mufflers are angled up, chances are the MAC pipes will be a bit lower, if anything, giving you more clearance rather than less.

Plan on replaceing the exhaust gaskets when you replace the system; buy them in advance as I don't think they come with the kit.

Let us know how they work out if you go this route.

[deo]

Thanks Jerry!

I liked the looks of the system and the sound I think I would like to have as it makes my presence known more quickly and hopefully the other vehicles around me will notice me.

On the other side, I really don't want more difficulty in changing tires but in somethings there is a trade off.

I haven't found a location for other than MAC exhaust systems. Is there another cost effective solution? I really don't want to try and find a pay for the Yamaha system. I understand that they think their system is made out of gold, not just a gold after firing color. Any recommendations on another solution?

dave

[Robert Haller]

Jardine makes exhaust pipes for XS1100's as well, I've got a set that I'm happy with. They may only offer megaphone style though.

[Jerry]

I have a Jardine 4 into 2 system (used) waiting to go my XJ. Going to fit them up when I pulled the stock pipes as part of the "2nd gear fix' the bike needs.

Yamaha no longer sells the stock system. I tried pricing mufflers about 2 years ago, right was out of production and left was $265.00. Even if you wanted to go this route Yamha couldn't supply all the parts.

Other than the MAC, not much else new available at reasonable prices. Some British and Australian posters have mentioned Motad systems; you might try searching past threads using "Mufflers" or "Exhaust" and see what turns up. Most of us keep an eye out on eBay for used Jardine, Kerker, or other systems that come up once in a while. Some are 4 into 1, others are 4 into 2. Jardine made both styles. Their 4 into 2 system incorporates the cross-over between the mufflers. 4 into 1 eliminates 1 muffler, making the system lighter.

The stock system is actually pretty decent. If your header pipes are OK, you might look into getting turn-out mufflers and adapting them to the head pipes. Adapters seem to be had fairly easily; the XS/XJ 1.5 inch diamter pipes are a bit small by modern standards, and most muflers will have a larger inlet. Most of your tme will be taken up mating the muffler hangers to the XJ's brackets.

[Jerry]

One other note....

Jardine still lists a 4 into 1 system for the XJ with choice of megaphone or oval canister systems. Price is about $345.00 plus shipping.

Not much info on the web page other than availability and price, but you can download the '03 catalog. Web page is at:

http://www.jardineproducts.com

Follow the Motorcycle link form the home page.

[deo]

Jerry,

I looked at their site and because I want to stay with a 4 - 2 setup thought that I would have to look for another arrangement.

My header pipes coming off the manifold are ugly and my left muffler has a hole, If I didn't have such ugly pipes I would just replace the left muffler.

I couldn't find out whether the MAC pipes have a cross over or not. Does anyone else know?

dave

[Tinman]

MAC Pipes

I have a set of MAC taper tips on mine.
They are kind of louder than I would like them to be.
But then that is just me.
But to answer your question they do not have a crossover pipe.
And you will have to custom bend the hanger brakets to get them to fit just right.
The good news is you can use the OEM bolt on the top end of the hanger bracket.
I can't remember where I got them from exactly since it has been a year now. And the first place I called to order them was out of stock at the time. I think I wound up ordering them from an outfit in Canada.

[deo]

Tinman and or Jerry,

When you say fit them does that mean a lot of metal bending or just a bit? Does an XS system fit differently than an XJ? I saw that you have an XS in your signature.

dave

[Jerry]

Again, getting into what I believe is correct, but don't have measurements to back this up.....

The XJ and XS header pipes whould be interchangeable and you shouldn't have problems bolting headers to the engine. Problem is in the rear muffler mounting bracket.

The XJ rear footpegs are about 2 inches farther forward than the XS Standard. Don't know about the Special but am told there is a difference between the Standard and Special footrest casting as well. (The XJ is patterened after the Special, so difference may not be as great.) If you look at the mounting bracket on a stock XJ muffler, it is a slot, so there is quite a bit of adjustment posible for forward - back positioning. The mounting bolt goes into the footrest casting.

Fitting XS or aftermarket mufflers means you will *probably* have to rig up an extension between the footrest casting mounting bolt and the bracket on the muffler. Most of the time this is not mechanically difficult, but might look ugly. One alternative is to weld a bracket to the new muffler in the correct location, but this will tend to mess up the chrome. I think Denny Zander came up with a clean solution, which involved making a 3-point bracket that attached to the footerest, frame above the footrest, and canister muffler he wanted to use. Looked sharp. I've also seen brackets held in place with Stainless Steel clamps or bands, which, because of their chome look, tends to be less obtrusive.

I don't mean to make this sound worse than it is, but in all likelyhood you will have to deal with some kind of adapter between the mounting bolt and muffler bracket. I plan to use a 2-point mount using the original mounting hole, (point 1) footpeg bolt, (point 2) and extend the bracket back just enough to mate with the Jardine muffler's original mounting bracket. Paint the bracket (1/4 inch flat stock) with black high temp paint and see how it looks. Hope to get this done next week, as that is when I plan to tackle the transmission work.

[strom]

Same problem here... looking for a decent 4 into 2 system... till a friend was fed up with my whining and decided to make me one. Should cost me bout 200$. We'll see.

LP