installed my new 4 to 1 exhaust, and having some leaking...

[ERM83]

saw something else...

I just went out to try a few things, but first:

the studs are the type that thread INTO the head, have a stop, then have threads for the nuts.

Here's the main thing I noticed, after a second look:

The old exhaust has a bit thinner plate, and ALSO, the stop ridge before the first bend on the pipe for the plate is further back, but there's more straight pipe on the old one for the plate to slide on.

I guess my only resort is to try some washers, but I don't have a lot of thread protruding from the tightened nuts as is. Any other ideas?? I'm stumped!

I'd have taken pictures, but I have to go to work, and had to put the new one back on right quick, as I don't have a garage...DAMN IT...

[ERM83]

Here's what's going on...






I dunno if the plates have to be modified, or what. Those plates won't go back on the pipe further than that. I don't know what to do...the only things I can think of are to half-crush another gasket, or liquid seal the s*** out of it. this is the third day that I've been messing with this; melting my brain trying to think of a solution. ANY advice would be awesome...I NEED this thing to run (and well at that). It's my only (and HEAVILY preferred) mode of transportation at the moment.

This is the 80' SG...can't believe I didn't mention that in the first place. AAAAHHHHH.....

[Rasputin]

OK, you are working on a special I guess, because SG and SF are in your signature space. You are also installing a 4 into 1 which is not OEM. I assume this it the first install attempt? I can tell you that specials and standards have different flanges for the pipes to connect to the heads. I think when I bought 4-1 Jardines, they gave me 4 flange adapters. If I remember correctly, I didn’t need them for the standard. What they do is slip over the pipes to extend the distance between the flange and the head and they contact the crush gaskets. I hope I am steering you right, it was a LONG time ago when the Jardine was installed. I don’t know why Yamaha changed the distances, but I suspect it had something to do with the mounts on the frame...

What skids said! It looks in the pictures like you are missing the flange adapters.

[bikerphil]

What is the thickness of the gaskets you have in there? There are different sizes. The ones I just measured here that I have are 4.5 mm thick, I have seen ones that are only 2mm.

[ERM83]

got them from mike's xs. this is driving me nuts. I've literally lost sleep over it!

I don't have my calipers on me, or I'd measure them right now. AAAGGGHHHH, THIS IS PISSING ME OFF!!!

[bikerphil]

If you used the mikesxs ones like in the link below, they look like they are the thicker ones.

https://www.mikesxs.net/yamaha-xs650...pe-gasket.html

[ERM83]

If you used the mikesxs ones like in the link below, they look like they are the thicker ones.

https://www.mikesxs.net/yamaha-xs650...pe-gasket.html

Yep...those are the ones! WHAT AM I MISSING HERE?! The (exhaust) kit specifically said that it fit 78-81 specials...I know that sometimes it can be misconstrued, but....FFFFF#*#&&%#%@*&&!!!!

I have so many things to do to this thing...of all of the things, I thought THIS would be the easiest. Carbwork is no problem to me anymore (thanks to you guys, and trying to troubleshoot stuff)...I was worried about the electrical work. NOT ANYMORE...

[Radioguylogs]

From the pictures, it looks like the nuts bottom out on the studs, like Phil said in posts #5 and #15....yet the flange has not pulled tight.

Is it possible the studs came out of the head via a PO and they were put back in with crud behind them, so they don't sit as deep as the other cylinders?

Seems like Phil's suggestion to use a washer(s) under the nuts is the lowest hanging fruit. The alternative is to remove the studs and change them somehow so more thread is available. Another crush gasket is a lower ranking alternative.

Just my way, but I wouldn't put goop in there. It's a mess for service and it just seems like a bad 'rig' job.

[DiverRay]

Radioguylogs:

From the pictures, it looks like the nuts bottom out on the studs, like Phil said in posts #5 and #15....yet the flange has not pulled tight.

If you look close, you will see the flange is against the head. Washers won't work. The half round flange adapters are too short by about 4mm. Easy fix is add a second exhaust gasket. Good fix is to find slightly longer flange adapters. You can also look at the flanges, and see if they are flat on both sides. If not, you can flip them so the flat side is towards the head and that may give you a little more.

[bikerphil]

The first pic looks like the flange is contacting the head itself and it can't go any further. If you have a bike shop around, maybe see if they have some of those thin 2mm copper gaskets and put them in there to take up space. You said only #1 is leaking now right?

Yes, if the nut is running out of threads on the stud, try a washer behind the nut, not gonna help if the flange is contacting the head, it should never do that.

[ERM83]

yeah, washers aren't gonna work...and I have NO IDEA where to even start with finding flange adaptors. I did try to experiment and line up with an extra washer, but then I didn't have enough thread to even put the nuts on. the copper gasket deal seems like the best route...but which ones / size to get?? Same question with the flange adaptors!

I'd like to get a backup pair of studs, anyway...want to have some just in case. I'm slowly working towards my full on rebuild of this thing, but I'm chipping away for now until I have another daily rider while working on the detrimental parts of the build. So, yeah...what kind / length of studs / where to get them would be much appreciated! I've been searching, but I'd rather ask you guys, who've owned these things for decades, rather than just pulling the trigger and ordering things.

This is a whole different experience for me...SO SORRY if these are dumb questions! I'm just frustrated beyond belief at this point, and just want to be WELL VERSED when it comes to the XS11's, so that I can help others all around! Between this, work, and doing other small maintenance on my beloved bike...my brain is GONE!

Eric

[ERM83]

OH...TOTALLY FORGOT to put this in the last post...on a closer look, I THINK that the stud on the bottom of #4 (I'm pretty sure that I said number one was leaking earlier...IT'S ACTUALLY NUMBER 4...SORRY AGAIN. MUSH-BRAIN) is slightly bent. I stared at it for a while, and it definitely looks a bit off. That's gotta be why it's leaking. It's leaking RIGHT AT THAT SPOT as well. Coming through the fins. It didn't leak with the last exhaust, though! I dunno what the hell is up with that...

Working too much + ADHD = JUMBLED POSTS. Feel free to smack me upside the head once I make one of these rallies...

[DiverRay]

what kind / length of studs / where to get them would be much appreciated! I've been searching, but I'd rather ask you guys, who've owned these things for decades, rather than just pulling the trigger and ordering things.

Easy, go to the auto parts store and get a set of studs/nuts for the newer smallblock Chevy, 8mm. I found a set in the red box on a rotating rack, about $7. If you need it, I can go downstairs and get the number off the package in the garage.
Be VERY careful pulling the old studs! They like to break! I've used heat from a propane torch to warm up the head around the stud, then hit it with a 50/50 mix of Acetone and GM auto trans fluid. One of the BEST oils for rusted bolts, and helps a bit with the aluminum oxide as well. Remember, sand paper is aluminum oxide, and it cuts right through steel!

[skids]

is slightly bent. I stared at it for a while, and it definitely looks a bit off. That's gotta be why it's leaking.

I doubt it unless you see evidence that the gasket was crushed outside of its edge. If the head pipe flange is flush against the head as it looks like in the pictures, I think it is not going into the cavity far enough to seal on the crush gaskets. Longer head bolts alone are not the fix... Now if you are thinking that longer head bolts might give more room for the nuts so that you can double-up on crush gaskets, or use thicker crush gaskets, you might be able to get it to work. I looked for my unused flange adapters for the Jardine header, but I couldn't find them. I think I threw them out when we moved.

[skids]

I thought you might be interested in reading this web page:

http://www.xs11.com/forum/showthread...&referrerid=69

Maybe it just confuses to whole issue.