Post by Steves 650 on Aug 31, 2008 11:00:07 GMT -5
I just finished putting exhaust gaskets on my new toy, '82 650 Heritage, and after playing around for a bit with the mufflers off I reinstalled them and found I still have some leaks, the front pipes both have a hole on the inner lower portion pointing toward the frame, I 'm thinking the guys before me were looking for a different sound or are these supposed to be there? Also, how would I tell if this bike is a SJ or S?
The stock headers are double walled. The functional pipe is inside the outer pipe, so if you are going to use the stock headers with an after market muffler, you need an adapter that will connect the muffler to the smaller inner pipe. And, yes...the outer pipe does have drain holes in them, so if you just clamp the muffler to the outer pipe, the exhaust will leak out of the drain holes.
The outer pipe may also leak at the head flange as well. The outer pipes were not designed to flow any exhaust, so there is no guarantee that they are gas tight from end to end.
I used this adapter on my '81/H:
This is a 1 1/2 X 1 3/8" adapter available at most auto supply stores, #548520. The small end will fit tightly around the outside of the inner pipe. Clamp the muffler around the large end. There is no way to clamp the small end around the inner pipe, but it fits real tight, so you can either wait for the carbon buildup to seal it or apply some Permatex muffler sealer.
The small end is completely hidden inside the header, the big end is completely hidden inside the muffler.
This is what it looks like when installed.
Last Edit: Jan 17, 2011 19:04:24 GMT -5 by pamcopete
I understand what your saying, I saw the inner pipe when I had the mufflers off. This is the original stock system and the holes are about 7/16" in size and on the side of the pipe, shouldn't they be smaller and on the bottom for drainage? I'm toying with the idea of welding them shut. Thanks for the info on the serial number and the pipe adapter.
Well, It isn't that simple. The outer pipe may also leak at the head flange as well. The outer pipes were not designed to flow any exhaust, so there is no guarantee that they are gas tight from end to end.
I think you will find the adapter idea easier and more effective.
Check out this link of another members experience with the same problem:
I installed the adapter pipes the other day, put a few tacks on them to just hold'em in place sounded 10 times better than when I brought her home, I'll see if the minor leaks "fix them selves" otherwise I'll finish seal them this winter. Thanks for the tip, I enjoyed the first ride to work today without sounding like a singer sewing machine! ;D
well let me just piggy back off this post. my setup also uses the stock heads and then straight pipes were welded on about a foot down. im guessing that the guy who made the pipes didn't use an adapter so i'm probably leaking exhaust gas through the outer wall right? would the best thing to do be to cut the pipes, get the adapter and re-weld the pipes?
Well, most people either ignore the double walled construction or are unaware of it and they just clamp or weld an aftermarket muffler or pipe to the outer pipe. There is a drain hole on the bottom inside that you could check to see if it is leaking exhaust. Also, the outer pipe will sometimes leak where it is welded at the exhaust flange.
If you detect leaks in these areas, then that pipe was probably just welded to the outer pipe and if you want to make it right, then you will have to cut it off and use the adapter.
Here are a couple of pics of the adapter and the inner pipe:
Last Edit: Aug 21, 2009 12:36:32 GMT -5 by pamcopete
Well, you should be able to hear it. If it is leaking at the header flange, it is a metalic sound when accelerating because of the high pressure in that area. If it is leaking at the drain hole, that that is more of "puff, puff, puff" sound when you decelerate.
I suggest that you get a file and smooth out the rough edges of both the inner pipe and the adapter. You want it to be tight for a leak proof joint because you can't clamp the inner pipe. You can either wait for the carbon build up to form a seal or use some Permatex muffler sealer.
Pamcopete, In your pic of the pipe showing the inner pipe. Could you take the headpipe to a muffler shop and have them expand the inner pipe to fit snuggly in the outer pipe and weld the two pipes together. Weld on a 2 inch extension the same size as outer pipe. This way you can just clamp the muffler onto the extension. Wouldn't this give a leakproof connection.
75 XS650B with 79 forks and dual disc, braided lines, disc brake on back, Pamco ignition, Pamcopete's reg/rec mods, kill switch relay, home made harness, all LED turn, brake and tail lights, tapered head bearings, bronze bushes in swing arm, soon to get shock and fork upgrades
Well, sure. The pipes are 30 years old and somewhat corroded, so welding may be difficult. Then there is the cost factor to weld two pipes. Welding will also destroy the chrome plating on the outer pipe. I think it wouldn't hurt to try the adapter fix first for about $6.
Here is a pic of the adapter and muffler. Notice how the original chrome plating is preserved:
Last Edit: Oct 14, 2010 20:03:22 GMT -5 by pamcopete
r80rt: :)This is a splendid write up, THANK YOU!!!!
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