Header Flanges

[jfmerk]

Moving on to the next problem while I re-test my carbs. I installed the exhaust assembly on cyl #4 only to find that I ran out of thread when tightening the nuts and the header was still loose, not even contacting the gasket. Here is what I found when I compared it to the # 2 & 3 header pipes.
Left is the #4 assembly, Right is the #3 header.



I bought the entire exhaust on ebay a year ago. The seller must have matched up two different years to make one complete system???

Can I stack two gaskets on top of each other?

Can I remove the flange and install the original one? Are they silver soldered on?

Thanks for any pointers!

[CatatonicBug]

Yes, you can stack gaskets. It's actually rather common. It looks like you have headers from a Standard AND a Special there. One is longer than the other, but I can't remember which is which.

[DiverRay]

The Standard is longer. You can also change the exhaust studs out for 5mm shorter ones. This will also allow the pipes to tighten properly.

[crazy steve]

This is probably another one of those weird little differences that crop up on these bikes...

I've got two 'standard' exhaust systems, and one is like yours; outboard flanges are shorter than the inboard flanges; I don't know what year this one is. But I've also got the original system for my '78, and all four flanges are the longer length, so somewhere along the way Yamaha shortened the outboard ones for some reason. So you probably have a 'matched set'. Interestingly enough, the Yamaha parts fiche shows the same number for '78-80 'standards' (the '81H used the 'special' exhaust), but I've got two 'types' so either the fiche is lying or the difference isn't supposed to matter.

Try putting some washers under the nuts on the outboard pipes, or you could swap to shorter studs.

'78E original owner

[jfmerk]

Thanks for the ideas guys. I think switching the studs is the best solution... but I'm so close to finishing my restoration, I can just see studs snapping off and I have a new project to deal with! They seem to be a very soft stud. So I think I'll take a chance with stacked gaskets.

Now that I think about it more, the exhaust system I bought from an ebayer was an OEM replacement, it has the riveted emission label on each muffler. So the owner probably bought the outboard muffler assemblies and re-used the 2 & 3 header pipes and later I bought the system.

I'll make'r work somehow, thanks again!

[TomRodgers]

(the '81H used the 'special' exhaust),

AH HA!!!! THAT is why when i bought the Jardine system off eBay for Ghost, the instructions called for "this" size ring and it didnt fit right......but i made it work with the "special" rings

[XS1100_OEM4ME]

Washer

Have you tried stacking flat washers between the allen nut and flange?

[jfmerk]

Actually, my plan was to stack two gaskets under the flange but that wasn't enough for it to tighten up, so out came my dremel with a cut-off wheel and I cut off about 3/16" from each stud. We're good to go now!

[WMarshy]

Hey guys,

Rather than starting a new thread I figured I would add to this one. I just bought a stock exhaust system and ran into the same problem. The raised flange on the down tubes are different between numbers 2,3 and 1,4. Cylinder #2 exhaust nuts tighten down properly but #1 exhaust nuts bottom out without clamping down the flange. Have about 3/16" or so to go for the number 1 and 4 flanges to tighten! Im trying to figure out my options. I don't have a hacksaw or anything, looks like the easiest thing to do at this point is stack washers under the nut... This sucks!

[XS1100_OEM4ME]

Washers

If you dont want to stack washers there are two other easy fixes. You can get auto hearer lock washers that will give you about a 1/4" of spacer and are still small enough diam. to fit in the flang hole, also they make a header nut that the threads run all the way through and have thin walls you drive with a small socket

[XS1100_OEM4ME]

link

Here are two links to show the kind of nuts and washers I am talking about just make sure you get the right size/thread for your bike. Can get at most hardware/auto parts stores

http://www.speedwaymotors.com/High-C...hers,1180.html

http://www.bgmfg.com/12_point_nuts.htm

[WMarshy]

Thanks for the links, I will be getting some new header nuts this week. I needed to ride the bike to work today so I had to settle for some SS washers to be able to ride. Luckily there was enough thread to get the washer and the nut on.