Stock Header to Muffler Seal

[Toolmaker Tim]

I have a set of stock Special pipes and mufflers that came with my 79F. The F came with the stock headers and a pair of turn-out mufflers that had a jury rigged cross over on them. I want to put the Special mufflers and pipes on my 79SF along with my rebuilt carbs that I set up at stock settings. I need the sleeve/spacer/seal that goes over the end of the mufflers and inside of the headers. Anybody know where I can get one or two of them?

[SFerinTEXAS]

Perhaps you have a set of XJ pipes. The special exhaust is solid from the outside head pipe to the end of the muffler. Only the 2 inside head pipes are removable. If that's the case those seals are the same as any XS pipe seal. Was a post about them a few weeks ago.Still available from the factory if all else fails.

[crazy steve]

Uhhh... the Special exhaust is one piece from the outside cylinders to the mufflers, so if you have two pieces, it's either non-stock or broken.

It's not a bolt-on either; there's enough differences to make this a pretty hard swap....

[Toolmaker Tim]

Ok, the header pipe is one piece down to the muffler, or is the muffler itself welded to the header pipe? My understanding (such as it is) was the headers came with the inside header a slip fit into the outside header pipe, then the mufflers were clamped onto the header pipe assembly, under the guard that covers the muffler/header clamp.

[crazy steve]

Ok, the header pipe is one piece down to the muffler, or is the muffler itself welded to the header pipe? My understanding (such as it is) was the headers came with the inside header a slip fit into the outside header pipe, then the mufflers were clamped onto the header pipe assembly, under the guard that covers the muffler/header clamp.

There's four pieces; the two inside header pipes, and the two outside header/collector/muffler/crossover assemblies. It's pretty common for them to cleanly break where the muffler is welded to the collector which might lead you to think it's supposed to be two parts, but they're not. Now, the XJ exhaust is very similar, does have separate mufflers, and will fit on a Special, but neither will easily fit on a standard frame.

The problem you'll have is the Special (and XJ) exhaust angles up/out compared to the standard exhaust, so the mufflers will hit the aluminum supports. You can't swap mounts between the frames because the mount holes are in different places and you would lose your standard rear brake pedal pivot.

You could have a spacer made at a muffler shop to bridge the gap and point the mufflers back straight, getting around the 'up' angle part. You would then have to change to Special center and side stands, as the standard units don't extend out far enough and will hit the mufflers before coming all the way up. That still may be a problem with the centerstand, because with the mufflers lower, the stand will be too.

[Toolmaker Tim]

XJ/SF to SF

Well, SFerrin may be right, it might be a XJ exhaust system. I'll have to check the numbers on the pipes and mufflers. I can understand mounting the exhaust on a standard would be a problem, but I am putting it on a Special, so it should work. I am going to put the set of Jardines I have on my SF on my 79F, so this should work. I'll mock it up here in a day or two and see how it hangs. As far as the seal goes, I can always turn up a set at work out of some copper. If it comes down to it I could always Tig weld it together. I'm going to have to weld the end pieces of the frame that the PO cut off back on anyway. As usual Steve, your knowledge of these bikes comes in handy. Between you and SFerrin you have been a big help. Thanks

[natemoen]

Well, SFerrin may be right, it might be a XJ exhaust system. I'll have to check the numbers on the pipes and mufflers. I can understand mounting the exhaust on a standard would be a problem, but I am putting it on a Special, so it should work. I am going to put the set of Jardines I have on my SF on my 79F, so this should work. I'll mock it up here in a day or two and see how it hangs. As far as the seal goes, I can always turn up a set at work out of some copper. If it comes down to it I could always Tig weld it together. I'm going to have to weld the end pieces of the frame that the PO cut off back on anyway. As usual Steve, your knowledge of these bikes comes in handy. Between you and SFerrin you have been a big help. Thanks

The Xj muffs are a slant cut on the end rather than the tapered ends that the xs has.