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Reinstalling Exhaust System

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  • Reinstalling Exhaust System

    As they say, you learn something new every day.

    I was struggling with the headers, trying to reinstall them with the whole system already assembled. ( I know I will hear about this one)

    If I may make a suggestion, DON'T. I'm sure someone else more knowledgable has already posted this but I thought I might reinforce it. Trying to lift that much weight, put the pipes into the head, jiggle so everything goes in... possible I guess but takes twice as long as disassembling and reassembling.

    I found the best way is #1 header/collector on first.

    Then #2 slips into the collector and then into the head.

    Then #4 header/collector and then #3.

    It was easy at that point.

    Another thing, when trying to put new gaskets (not exhaust, the ones where pipes connect) the originals are a bear to remove. Thank the lord for a seal puller. They were metal and asbestos and had really locked into the pipes. Actually the new ones look sorta crappy but I guess they will do.

    So now my XJ project has gone from restoring, to refurbishing to just get the damn thing back together so you can ride. God bless the people that can make everything shine. I'm not one of them.
    82 XJ100J Gone
    83 XJ750 Seca
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