Exhaust gaskets

As long as I have the exhaust off, I'd like to replace the exhaust gaskets from where the pipes meet the head. Since there are no gaskets there now, I don't know what I need. Are these (yet another) special order item or are they "common" to the point where many bikes use them and I can find them locally? Can I buy some "material" and make them myself? Any help is appreciated.

 

PM chacal! I'm sure he might have what ur lookin' 4.. He is the "Resident parts GURU!!"

 

they are about 1/8 inch thick, made of metal & fibre.
Chacal probably has them in stock.

 

I would try bike shop, all you need is 40mm gasket and they are quite common between bikes.

 

Quite so.

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a9) OEM and aftermarket cylinder head Exhaust Port Ring Gasket....the thin "doughnut" ring gasket between the cylinder head and the exhaust header pipe. A very common source of leaks. You ALWAYS replace these whenever you remove your exhaust header(s). Aftermarket reproductions fit and seal just like the originals.


HCP583 OEM cylinder head Exhaust Port-to-Header pipe Ring Gasket, fits all XJ550, XJ650, XJ700, XJ750, and XJ900RK models. Each:
$ 4.25

HCP583SET4 OEM cylinder head Exhaust Port-to-Header pipe Ring Gasket, set of 4:
$ 16.00


HCP1617 Aftermarket cylinder head Exhaust Port-to-Header pipe Ring Gasket, fits all XJ550, XJ650, XJ700, XJ750, and XJ900RK models., each:
$ 2.50

HCP1617SET4 Aftermarket cylinder head Exhaust Port-to-Header pipe Ring Gasket, set of 4:
$ 9.50

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Had I known about Chacal earlier, I wouldn't have had to get my last set from eBay. They weren't even for the XJ bikes, but they were indeed common enough that they fit just fine.

 

LOOK CLOSELY! I didn't think the PO had used any when he installed the system I pulled off but they were in there, MASHED into the ports, I had to more or less dig them out. Replace them of course but you may find there are some in there...

 

I ( being the cheap #&&%#%* that I am) reused mine.
I cleaned them with solvent and then used some ultra copper silicone on both sides. No leaks in 1000 miles.

 

so did I.

 

The Exhaust Gaskets are probably in there and you can't see them because they look like part of the head.

Use a pick and probe the center of the exhaust port and see if its metal or fiber.

If you can pull those Exhaust Flange Donuts without tearing them ... you can treat them with a Heavy Duty Sealant and re-use them.

Permatex High-heat High-Tack Spray-a-Gasket will do the trick.
Spray both sides of the gasket.
Twice.
Shoot some in a tuna can and paint some on the surface of the exhaust port.

Shouldn't leak 'til you change them for new ones someday.

 

Gaskets-R-Us:

It's an "exhausting" list to go through, I know.........


EXHAUST SYSTEM PARTS:



Cylinder Head Exhaust Port Gaskets:


a9) OEM and aftermarket cylinder head Exhaust Port Ring Gasket....the thin "doughnut" ring gasket between the cylinder head and the exhaust header pipe. A very common source of leaks. You ALWAYS replace these whenever you remove your exhaust header(s). Aftermarket reproductions fit and seal just like the originals.


HCP583 OEM cylinder head Exhaust Port-to-Header pipe Ring Gasket, fits all XJ550, XJ650, XJ700, XJ750, and XJ900RK models. Each:
$ 4.25

HCP583SET4 OEM cylinder head Exhaust Port-to-Header pipe Ring Gasket, set of 4:
$ 16.00


HCP1617 Aftermarket cylinder head Exhaust Port-to-Header pipe Ring Gasket, fits all XJ550, XJ650, XJ700, XJ750, and XJ900RK models., each:
$ 2.50

HCP1617SET4 Aftermarket cylinder head Exhaust Port-to-Header pipe Ring Gasket, set of 4:
$ 9.50



HCP1253 OEM cylinder head Exhaust Port-to-Header pipe Ring Gasket, fits all XJ1100 models, each:
$ 3.50

HCP1253SET4 OEM cylinder head Exhaust Port-to-Header pipe Ring Gasket, fits all XJ1100 models, set of 4:
$ 12.50


HCP1618 Aftermarket exhaust Port-to-Headpipe Ring Gasket, fits all XJ1100 models, each:
$ 2.50

HCP1618SET4 Aftermarket exhaust Port-to-Headpipe Ring Gasket, fits all XJ1100 models, set of 4:
$ 9.50



Header Pipe Outlet to Exhaust Collector Inlet Gaskets:


a29) OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket....these thick doughnut and flange gaskets are used in various places on your exhaust system, and are a common source of leaks. You should carefully inspect and replace any worn or damaged originals whenever you remove your exhaust system components.


HCP584 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket......where each headpipe ends and joins into the collector is where you'll find these gaskets. Use 1 per pipe joint, 4 per bike. For use on all XJ550, XJ650 Seca and Turbo models, and all XJ750 models. Each:
$ 22.00

HCP584SET4 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket. Set of 4:
$ 82.00



HCP585 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket......where each headpipe ends and joins into the collector is where you'll find these gaskets. Use 1 per pipe joint, 4 per bike. For use on all XJ650 Maxim and Midnight Maxims, and all XJ700 models. Each:
$ 10.00

HCP585SET4 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket. Set of 4:
$ 36.00



HCP2621 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket......where each headpipe ends and joins into the collector is where you'll find these gaskets. Use 1 per pipe joint, 4 per bike. For use on all XJ900 models. Each:
$ 12.00

HCP2621SET4 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket. Set of 4:
$ 44.00



HCP588 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket. Use 1 per pipe joint, 4 per bike. For use on all XJ1100 models. Each:
$ 14.00

HCP588SET4 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket. Set of 4:
$ 49.00



Exhaust Crossover Pipe Joint Gaskets:

a30) OEM exhaust system Crossover Pipe Joint Gasket....these thick doughnut gaskets are used where the left-to-right collector (XJ650 Maxim) or the left-to-right muffler can (XJ1100) crossover pipes join, and are a common source of leaks. You should carefully inspect and replace any worn or damaged originals whenever you remove your exhaust system components. Use 1 per bike.


HCP584 OEM exhaust system Crossover Pipe Joint Gasket. For use on all XJ650 Maxim and Midnight Maxim models.
$ 22.00


HCP588 OEM exhaust system Crossover Pipe Joint Gasket. For use on all XJ1100 models.
$ 14.00




Collector Box Outlet to Muffler Can Inlet Gaskets:

a30) OEM exhaust system Collector Outler-to-Muffler Can Inlet Gasket. These doughnut gaskets are used at the rear of the system collector, and joint the muffler can inlet, and are a common source of leaks. Use 1 gasket per muffler, 2 per bike. You should carefully inspect and replace any worn or damaged originals whenever you remove your exhaust system components.


HCP588 OEM exhaust system Collector Outlet-to-Muffler Can Inlet Gasket. For use on all XJ550 models, XJ650 Seca models, all XJ750 models, XJ900, and XJ1100 models. Each:
$ 14.00

HCP588SET2 OEM exhaust system Collector Outlet-to-Muffler Can Inlet Gasket. Set of 2:
$ 26.00


HCP2621 OEM exhaust system Collector Outlet-to-Muffler Can Inlet Gasket. For use on all XJ700 models. Each:
$ 12.00

HCP2621SET2 OEM exhaust system Collector Outlet-to-Muffler Can Inlet Gasket. Set of 2:
$ 23.00


HCP2624 OEM exhaust system Turbo Joint Pipe-to-Muffler Can Inlet Gasket. Where the right side turbo outlet joint pipe outlet pipe ends and joins into the right muffler can inlet is where you'll find this gasket. Use 1 gasket per bike. For use on all XJ650 Turbo models.
$ 21.00



Exhaust Collector and Muffler Can Hardware:


eh5) Original and aftermarket Exhaust System Hardware perfectly replaces the stripped, damaged, rusted or missing originals. It is always a great idea to replace these hardware items whenever you have your system apart. And as usual, PLEASE always use anti-seize compound on the threads of any exhaust system fastener during assembly!

Exhaust system hardware is listed below BY MODEL. Within each model listing, the hardware products list starts at the "beginning" of the exhaust system---meaning where the header pipes attach to the cylinder head exhaust port----and then proceed from there, more-or-less in the following order (some models vary slightly in their layout and orientation):

* the cylinder head Threaded Studs, their Flanged Nuts, and the large finned, cast aluminum Ring Nut---which of course really isn't a nut at all! By the way, I can't stress just how great an idea it is to replace the flange nuts whenever you remove your originals, for whatever reason.

* the header pipe exhaust gas analysis test port Bolt and its Washer.

* the joint where the header pipe outlet fits into the collector box inlet. On most models, the pinch clamp at this joint is permanently attached to the collector box inlet, and the only replacable items are the pinch clamp Bolt and Washer. The XJ1100 models are the only ones that use replacable Pinch Clamps, in addition to the fasteners.

* the collector box attaching hardware needed to secure the collector box---and by design, to also support the weight of almost the entire exhaust system----to the frame. Varies by model, but usually consists of a Bolt that goes through the collector box, which is then insulated by rubber dampers, and which attaches via a Collar to a "u"-shaped metal Bracket. This Bracket is then attached to the bike frame via two Bolts and Washers.

It should be noted that worn insulators (dampers) in this part of your exhaust system can lead to excessive vibration (buzzing) in the system, and it is recommended that you periodically inspect them for integrity and the mounting hardware in this critical area for security and correct tightness.

Also, note that XJ650 Maxim and Midnight Maxim models, as well as XJ1100 models, do not use a "collector box" and thus there is no associated exhuast system-to-frame mounting hardware, brackets, etc. on those models.

* the joint where the collector box outlet (or equivalent) fits into the muffler inlet stub pipe. On most models, the Pinch Clamp at this joint is permanently attached to the muffler inlet stub pipe, and the only replacable items are the pinch clamp Bolt and Washer. XJ1100 models are the only ones that use replacable Pinch Clamps, in addition to the fasteners.

* finally, our tour ends at the muffler bracket-to-footrest bracket (or frame) mounting Bolt, Washer, and Nuts, as well as the rubber bumper that is mounted on the left muffler can to cushion against the centerstand while it is in the "up" position.


NOTE: for XJ550 and XJ650 models, the HCP577 exhaust header pipe Ring Nut is a bright, semi-polished natural aluminum, while the HCP578 Ring Nut is black-plated. Since both ring nuts share all the same critical dimensions, the black HCP578 ring nut can be used in place of the natural-finish HCP577 ring nut on all engines for a more aggressive appearance.


The prices for each piece of hardware are listed at the end of this section.


XJ550 all Maxim and Seca models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe: HCP577


- OEM header pipe gas analysis test port Bolt, use 1 per pipe: HCP2182
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe: HCP2173


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP2181
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP2537


- OEM collector (rear) to frame mounting Bolt, use 1 per bike: HCP3931
- OEM collector (rear) to frame mounting bolt Washer, use 1 per bike: HCP3946
- OEM collector (rear) to frame mounting rubber Insulator (damper), use 2 per bike: HCP2637
- OEM collector (rear) to frame mounting rubber insulator metal Collar, use 1 per bike: HCP2634


- OEM collector outlet-to-muffler inlet clamp Bolt, use 1 per muffler: HCP3925
- OEM collector outlet-to-muffler inlet clamp bolt Washer, use 1 per muffler: HCP2537


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, use 1 per side: HCP3930
- OEM muffler frame mounting bracket bolt Oval Nut, use 1 per side: HCP3942


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2640



XJ650 all Maxim and Midnight Maxim models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe, XJ650 Maxim models: HCP577
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe, XJ650 Midnight Maxim models: HCP578


- OEM header pipe gas analysis test port Bolt, use 1 per pipe, XJ650 Maxim models: HCP2182
- OEM header pipe gas analysis test port Bolt, use 1 per pipe, XJ650 Midnight Maxim models: HCP3933
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe, XJ650 Maxim models: HCP2173
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe, XJ650 Midnight Maxim models: HCP1869


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe, XJ650 Maxim models: HCP3925
- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe, XJ650 Midnight Maxim models: HCP3928
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, XJ650 Maxim models, use 1 per pipe: HCP2537
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, XJ650 Midnight Maxim models, use 1 per pipe: HCP3945


- OEM left-to-right crossover pipe clamp Bolt, XJ650 Maxim models, use 1: HCP3925
- OEM left-to-right crossover pipe clamp Bolt, XJ650 Midnight Maxim models, use 1: HCP3928
- OEM left-to-right crossover pipe clamp bolt Washer, XJ650 Maxim models, use 1: HCP2537
- OEM left-to-right crossover pipe clamp bolt Washer, XJ650 Midnight Maxim models, use 1: HCP3945


- OEM #1 and #4 header pipe outlet-to-collector inlet clamp panhead Screw, XJ650 Maxim and Midnight Maxim models, use 1 per side: HCP3926
- OEM #1 and #4 header pipe outlet-to-collector inlet clamp screw Washer, XJ650 Maxim models, use 1 per side: HCP2173
- OEM #1 and #4 header pipe outlet-to-collector inlet clamp screw Washer, XJ650 Midnight Maxim models, use 1 per side: HCP1869


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, XJ650 Maxim models, use 1 per side: HCP3930
- OEM muffler bracket-to-frame bracket mounting Flange Bolt, XJ650 Midnight Maxim models, use 1 per side: HCP3931
- OEM muffler frame mounting bracket bolt Washer, use 1 per side: HCP3946
- OEM muffler frame mounting bracket bolt Oval Nut, use 1 per side: HCP3942


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



XJ650RJ Seca models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe: HCP577


- OEM header pipe gas analysis test port Bolt, use 1 per pipe: HCP2182
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe: HCP2173


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP2181
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP2537


- OEM collector (rear) to frame bracket mounting Bolt, use 1 per bike: HCP3931
- OEM collector (rear) to frame mounting rubber Insulator (damper), use 2 per bike: HCP2637
- OEM collector (rear) to frame mounting Frame Bracket, use 1 per bike: HCP2632
- OEM collector (rear) to frame mounting rubber insulator metal Collar, use 1 per bike: HCP2635
- OEM frame bracket-to-frame mounting Bolt, use 2 per bike: HCP3925
- OEM frame bracket-to-frame mounting bolt Washer, use 2 per bike: HCP2537


- OEM collector outlet-to-muffler inlet clamp Bolt, use 1 per muffler: HCP3925
- OEM collector outlet-to-muffler inlet clamp bolt Washer, use 1 per muffler: HCP2537


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, use 1 per side: HCP3936
- OEM muffler bracket-to-frame mounting bolt Washer, use 1 per side: HCP3946
- OEM muffler bracket-to-frame mounting bolt Oval Nut, use 1 per side: HCP3942


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



XJ650 Turbo models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe: HCP578


- OEM header pipe gas analysis test port Bolt, use 1 per pipe, 1982 XJ650 Turbo models: HCP3933
- OEM header pipe gas analysis test port Bolt, use 1 per pipe, 1983 XJ650 Turbo models: HCP3935
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe, 1982 XJ650 Turbo models: HCP2173
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe, 1983 XJ650 Turbo models: HCP4108


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP2181
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP2537


- OEM collector (rear) to frame bracket mounting Bolt, use 1 per bike: HCP3931
- OEM collector (rear) to frame mounting rubber Insulator (damper), use 2 per bike: HCP2637
- OEM collector (rear) to frame mounting Frame Bracket, use 1 per bike: HCP2632
- OEM collector (rear) to frame mounting rubber insulator metal Collar, use 1 per bike: HCP2635
- OEM frame bracket-to-frame mounting Bolt, use 2 per bike: HCP3925
- OEM frame bracket-to-frame mounting bolt Washer, use 2 per bike: HCP2537


- OEM left muffler inlet flange-to-turbo outlet Bolt, XJ650 Turbo models, use 1 per bike: HCP3934
- OEM left muffler inlet flange-to-turbo outlet stud Nut, 1982 XJ650 Turbo models, use 2 per bike: HCP2617
- OEM left muffler inlet flange-to-turbo outlet stud Nut, 1983 XJ650 Turbo models, use 2 per bike: HCP3943


- OEM right muffler inlet flange-to-turbo outlet short Bolt, use 1 per bike: HCP8350
- OEM right muffler inlet flange-to-turbo outlet middle-length Bolt, use 1 per bike: HCP3925
- OEM right muffler inlet flange-to-turbo outlet long Bolt, use 1 per bike: HCP8351
- OEM right muffler inlet flange-to-turbo outlet middle-length bolt Washer, use 1 per bike: HCP2537


- OEM left muffler bracket-to-frame mounting Flange Bolt, use 1 per bike: HCP4049
- OEM right muffler bracket-to-frame front mounting Flange Bolt, use 1 per bike: HCP4956
- OEM right muffler bracket-to-frame rear mounting Flange Bolt, use 1 per bike: HCP4049
- OEM left muffler bracket-to-frame mounting bolt Nut, use 1 per side: HCP4034
- OEM right muffler-to-frame mounting bracket front bolt Nut, use 1 per side: HCP6264
- OEM right muffler-to-frame mounting bracket rear bolt Nut, use 1 per side: HCP4034


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



XJ700 all models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, all XJ700 non-X models, use 1 per pipe: HCP579
- OEM header pipe large finned, cast aluminum Ring Nut, all XJ700-X models, use 1 per pipe: HCP580


- OEM header pipe gas analysis test port Bolt, use 1 per pipe: HCP3572
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe: HCP2173


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP3928
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP3945


- OEM collector (rear) to frame bracket mounting Bolt, use 1 per bike: HCP3931
- OEM collector (rear) to frame mounting rubber Insulator (damper), use 2 per bike: HCP2637
- OEM collector (rear) to frame mounting Frame Bracket, use 1 per bike: HCP3736
- OEM collector (rear) to frame mounting rubber insulator metal Collar, use 1 per bike: HCP2635
- OEM frame bracket-to-frame mounting Bolt, use 2 per bike: HCP3925
- OEM frame bracket-to-frame mounting bolt Washer, use 2 per bike: HCP2537


- OEM collector outlet-to-muffler inlet clamp Bolt, use 1 per muffler: HCP3925
- OIEM collector outlet-to-muffler inlet clamp bolt Washer, use 1 per muffler: HCP2537


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, use 1 per side: HCP3939
- OEM muffler frame mounting bracket bolt Washer, use 1 per side: HCP3947


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



u]XJ750 all Maxim, Midnight Maxim, and Seca models:[/u]

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe: HCP579


- OEM header pipe gas analysis test port Bolt, use 1 per pipe, 1982 XJ750 Maxim and all XJ750 Seca models: HCP2182
- OEM header pipe gas analysis test port Bolt, use 1 per pipe, 1983 XJ750 Maxim and Midnight Maxim models: HCP3572
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe, XJ750 Maxim and XJ750 Seca models: HCP2173
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe, X750 Midnight Maxim models: HCP1869


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP3927
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP3945


- OEM collector (rear) to frame bracket mounting Bolt, use 1 per bike: HCP3931
- OEM collector (rear) to frame mounting rubber Insulator (damper), use 2 per bike: HCP2637
- OEM collector (rear) to frame mounting Frame Bracket, use 1 per bike: HCP2632
- OEM collector (rear) to frame mounting rubber insulator metal Collar, use 1 per bike: HCP2635
- OEM frame bracket-to-frame mounting Bolt, all XJ750 Maxim and XJ750 Seca models, use 2 per bike: HCP3925
- OEM frame bracket-to-frame mounting Bolt, all XJ750 Midnight Maxim models, use 2 per bike: HCP3928
- OEM frame bracket-to-frame mounting bolt Washer, all XJ750 Maxim and XJ750 Seca models, use 2 per bike: HCP2537
- OEM frame bracket-to-frame mounting bolt Washer, XJ750 Midnight Maxim models, use 2 per bike: HCP3945


- OEM collector outlet-to-muffler inlet clamp Bolt, all XJ750 Maxim and XJ750 Seca models, use 1 per muffler: HCP3925
- OEM collector outlet-to-muffler inlet clamp Bolt, XJ750 Midnight Maxim models, use 1 per muffler: HCP3928
- OEM collector cover-to-clamp (rear) clamp Screw, XJ750 Seca models, use 1 per muffler: HCP2264
- OEM collector cover-to-clamp (rear) clamp screw Washer, XJ750 Seca models, use 1 per muffler: HCP2173
- OEM collector outlet-to-muffler inlet clamp bolt Washer, all XJ750 Maxim and XJ750 Seca models, use 1 per muffler: HCP2537
- OEM collector outlet-to-muffler inlet clamp bolt Washer, XJ750 Midnight Maxim models, use 1 per muffler: HCP3945


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, 1982 XJ750 Maxim models, use 1 per side: HCP3931
- OEM muffler bracket-to-frame bracket mounting Flange Bolt, 1983 XJ750 Maxim and Midnight Maxim models, use 1 per side: HCP3938
- OEM muffler bracket-to-frame bracket mounting Flange Bolt, all XJ750 Seca models, use 1 per side: HCP3937
- OEM muffler bracket-to-frame mounting bolt Washer, 1982 XJ750 Maxim models, use 1 per side: HCP3946
- OEM muffler frame mounting bracket bolt Oval Nut, use 1 per side: HCP3942


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



XJ900RK Seca models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe: HCP580


- OEM collector gas analysis test port Bolt, use 1 per pipe: HCP3572
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe: HCP2173


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP3925
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP2537


- OEM collector (rear) to frame bracket mounting Bolt, use 1 per bike: HCP3931
- OEM collector (rear) to frame mounting rubber Insulator (damper), use 2 per bike: HCP2637
- OEM collector (rear) to frame mounting Frame Bracket, use 1 per bike: HCP2632
- OEM collector (rear) to frame mounting rubber insulator metal Collar, use 1 per bike: HCP2635
- OEM frame bracket-to-frame mounting Bolt, use 2 per bike: HCP3925
- OEM frame bracket-to-frame mounting bolt Washer, use 2 per bike: HCP2537


- OEM collector outlet-to-muffler inlet clamp Bolt, use 1 per muffler: HCP3925
- OEM collector outlet-to-muffler inlet clamp bolt Washer, use 1 per muffler: HCP2537


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, use 1 per side: HCP3929
- OEM muffler frame mounting bracket bolt Nut, use 1 per side: HCP4034


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



XJ1100 Maxim models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2942
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP2617
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe, XJ650 Maxim models: HCP2615


- OEM header pipe gas analysis test port Bolt, use 1 per pipe: HCP2182
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe: HCP2173


- OEM #2 header pipe outlet-to-collector inlet Clamp, use 1: HCP3940
- OEM #3 header pipe outlet-to-collector inlet Clamp, use 1: HCP3941
- OEM #2 and #3 header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP3925
- OEM #2 and #3 header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP2537


- OEM left collector pipe outlet-to-muffler inlet Clamp, use 1: HCP3940
- OEM right collector pipe outlet-to-muffler inlet Clamp, use 1: HCP3941
- OEM collector pipe outlet-to-muffler inlet clamp Bolt, use 1 per muffler: HCP3925
- OEM collector pipe outlet-to-muffler inlet clamp bolt Washer, use 1 per muffler: HCP2537


- OEM left-to-right crossover pipe Clamp, use 1: HCP3940
- OEM left-to-right crossover pipe clamp Bolt, use 1: HCP3925
- OEM left-to-right crossover pipe clamp bolt Washer, use 1: HCP2537


- OEM #1 and #4 collector pipe chrome cover Bolt, use 2 per side: HCP3572
- OEM #1 and #4 collector pipe chrome cover bolt Washer, use 2 per side: HCP8355


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, use 1 per side: HCP3931
- OEM muffler frame mounting bracket bolt Washer, use 1 per side: HCP3946
- OEM muffler frame mounting bracket bolt Oval Nut, use 1 per side: HCP3942


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



PRICES FOR EXHAUST SYSTEM HARDWARE LISTED ABOVE:

Bolts, Screws and Studs:

HCP2181 Bolt, each: $ 2.00
HCP2181SET4 Bolts, set of 4: $ 7.00

HCP2182 Bolt, each: $ 2.50
HCP2182SET4 Bolts, set of 4: $ 8.50

HCP2264 Screw, each: $ 1.50
HCP2264SET2 Screws, set of 2: $ 2.75

HCP2941 Stud, each: $ 1.50
HCP2941SET2 Studs, set of 2: $ 2.75
HCP2941SET8 Studs, set of 8: $ 11.00

HCP2942 Stud, each: $ 3.00
HCP2942SET2 Studs, set of 2: $ 5.75
HCP2942SET8 Studs, set of 8: $ 20.00

HCP3572 Bolt, each: $ 1.75
HCP3572SET4 Bolts, set of 4: $ 6.50

HCP3925 Bolt, each: $ 1.25
HCP3925SET2 Bolts, set of 2: $ 2.25
HCP3925SET4 Bolts, set of 4: $ 4.25

HCP3926 Screw, each: $ 1.00
HCP3926SET2 Screws, set of 2: $ 1.75

HCP3927 Bolt, each: $ 2.00
HCP3927SET4 Bolts, set of 4: $ 7.00

HCP3928 Bolt, each: $ 1.25
HCP3928SET2 Bolts, set of 2: $ 2.25
HCP3928SET4 Bolts, set of 4: $ 4.25

HCP3929 Bolt, each: $ 2.25
HCP3929SET2 Bolts, set of 2: $ 4.25

HCP3930 Bolt, each: $ 4.50
HCP3930SET2 Bolts, set of 2: $ 8.50

HCP3931 Bolt, each: $ 1.50
HCP3931SET2 Bolts, set of 2: $ 2.75

HCP3933 Bolt, each: $ 1.00
HCP3933SET4 Bolts, set of 4: $ 3.25

HCP3934 Bolt, each: $ 1.50

HCP3935 Bolt, each: $ 1.50
HCP3935SET4 Bolts, set of 4: $ 5.00

HCP3936 Bolt, each: $ 3.00
HCP3936SET2 Bolts, set of 2: $ 5.50

HCP3937 Bolt, each: $ 2.50
HCP3937SET2 Bolts, set of 2: $ 4.75

HCP3938 Bolt, each: $ 7.00
HCP3938SET2 Bolts, set of 2: $ 13.50

HCP3939 Bolt, each: $ 1.50
HCP3939SET2 Bolts, set of 2: $ 2.75

HCP4049 Bolt, each: $ 3.00

HCP4956 Bolt, each: $ 1.95

HCP8350 Bolt, each: $ 1.00

HCP8351 Bolt, each: $ 1.50



Washers:

HCP1869 Washer, each: $ 1.00
HCP1869SET2 Washers, set of 2: $ 1.50
HCP1869SET4 Washers, set of 4: $ 2.50

HCP2173 Washer, each: $ 1.00
HCP2173SET2 Washers, set of 2: $ 1.50
HCP2173SET4 Washers, set of 4: $ 2.50

HCP2537 Washer, each: $ 1.00
HCP2537SET2 Washers, set of 2: $ 1.50
HCP2537SET4 Washers, set of 4: $ 2.50

HCP3945 Washer, each: $ 1.00
HCP3945SET2 Washers, set of 2: $ 1.50
HCP3945SET4 Washers, set of 4: $ 2.50

HCP3946 Washer, each: $ 2.50
HCP3946SET2 Washers, set of 2: $ 4.75

HCP3947 Washer, each: $ 4.75
HCP3947SET2 Washers, set of 2: $ 9.00

HCP4108 Washer, each: $ 1.00
HCP4108SET4 Washers, set of 4: $ 3.50

HCP8355 Washer, each: $ 1.25
HCP8355SET4 Washers, set of 4: $ 4.50




Nuts and Ring Nuts:

HCP577 Ring Nut, each: $ 22.00
HCP577SET4 Ring Nuts, set of 4: $ 82.00

HCP578 Ring Nut, each: $ 17.00
HCP578SET4 Ring Nuts, set of 4: $ 64.00

HCP579 Ring Nut, each: $ 24.00
HCP579SET4 Ring Nuts, set of 4: $ 89.00

HCP580 Ring Nut, each: $ 17.50
HCP580SET4 Ring Nuts, set of 4: $ 66.00

HCP581 Flange Nut, each: $ 2.00
HCP581SET2 Flange Nuts, set of 2: $ 3.95
HCP581SET8 Flange Nuts, set of 8: $ 13.00

HCP2615 Ring Nut: no longer available

HCP2617 Nut, each: $ 4.50
HCP2617SET2 Nuts, set of 2: $ 8.00
HCP2617SET8 Nuts, set of 8: $ 29.50

HCP3942 Nut, each: $ 6.50
HCP3942SET2 Nuts, set of 2: $ 12.50

HCP3943 Nut, each: $ 5.00
HCP3943SET2 Nuts, set of 2: $ 9.50

HCP4034 Nut, each: $ 1.25
HCP4034SET2 Nuts, set o 2: $ 2.25

HCP6264 Nut, each: $ 8.50


Brackets, Clamps, Collars, Insulators, Stoppers:


HCP2632 Bracket, each: $ 36.00

HCP2634 Collar, each: $ 8.00
HCP2635 Collar, each: $ 12.00

HCP2637 Damper, each: $ 8.00
HCP2637SET2 Dampers, set of 2: $ 15.00

HCP2639 Bumper, each: $ 7.00
HCP2640 Bumper, each: $ 4.00

HCP3736 Bracket: no longer available

HCP3940 Clamp, each: $ 12.00
HCP3940SET2 Clamps, set of 2: $ 23.00
HCP3940SET3 Clamps, set of 3: $ 34.00

HCP3941 Clamp, each: $ 12.00
HCP3941SET2 Clamps, set of 2: $ 23.00

 

I'm just a newb but I just replaced my exhaust with an original mint '82 one from Ebay. Upon removal I didn't think there were seals in there. A tap on a flathead screwdriver about 1/16 of an inch in from the edge changed my mind. They came out real easy and I splurged for 4 new ones at 8 bucks a piece. The Yamaha dealer stocks them and they look to be copper. My bike is quiet as a mouse now and pulls like a raped ape.
The old seals were flattened really bad from the PO tightening the crap out of the nuts.

 

Yup, they were in there and in naaaaasty shape. Half of one was missing. Probably down in the pipes somewhere.

These are the copper "crush" type. I'll hit up Yamaha tomorrow and see if they have them or the fiber ones in stock. I also have an independent shop close by. If neither has them, I'll order from Chacal. My local Yamaha takes forever to get parts in and they don't stock much. My last order took more than two weeks to arrive.

 

They're Exhaust Flange Donuts.
You don't need an OEM Part.
They're pretty generic.

You should be able to stop-in at any Jap Bike Shop and pick-up a set.
Measure the Outside Diameter of one you pulled-out in decent shape and tell the Parts Guy what size they are and he'll hand you four.

He might even have a Parts Book that will have the size needed for your Bike.

 

You can pick up a set cheap from Chacal, he's got them in stock and ships immediately.

 

After I reshimed 2 of my tight exhaust valves on 3 and 4 I developed/noticed an exhaust leak. (at least I hope that is all it is - sounds like a little hammer tapping on cyl 3 that appears loudest next to the header nut).

I pulled the headers (first time I got lucky on this bike and they came off with no problems). The doughnuts look to be in great shape so based on Rick's advice above I will reinstall with permatex tomorrow. I even see carbon on the edge of #3's doughnut and the others are clean so I suspect it is the cause of the leak.

My question is - the doughnuts did not have any sealant on them it appears. Would you normally install new ones with no sealant?

 

Normally, you don't need Sealant with Brand New Donuts.

The Sealant is used if the Donuts arent burned through and you want to re-use them.

Coat BOTH Side with Sealant and Paint some sealant on the flat shelf the Donut contacts on the Head.

 

Are you SURE sealant isn't just a waste of...sealant? I think the mechanical squashing is the sealing factor, and just like a spark plug's squish ring, they can be reused if they aren't completely mashed flat to the point of having no "body" left. I don't think even the best gasket sealer is made to withstand the kind of temps that occur right where the pipe meets the head. They KEEP working (unless completely hammered out) because they are "in compression" and act as a buffer between the different expansion rates when the aluminum head and the steel pipes get hot. This (plus the "commonly available" factor) is why I use Jap exhaust pipe seals in my Norton. The original ones are hollow like a spark plug ring and only mash ONCE. (then they disintegrate from vibration but that's not a Yamaha issue...)

 

Permatex High-temp Spray-a-Gasket

http://www.midwayautosupply.com/pc-1433 ... 80697.aspx

This stuff is the best money you'll ever spend. If the Gaskets are leaking-by ... this stops it.

Period.

 

Thanks! my gaskets look great - not torn or smashed - I suspect the nut may have been slightly loose. I'm thinking it can't hurt to use the sealant when I reinstall.

One more question. After posting last night I decided to clean my header pipes while they were off. I found a lot of carbon on the #2 header where it goes into the rest of the pipes (not sure of the correct term). I remember thinking the bolt was a bit loose when I took them off. I know the noises can fool you in origin, I would swear the noise I hear was on the right side near #3.

Would an exhaust leak there also make a pinging or tapping sound?

I'm going to get the sealant and reassemble after work today so hopefully the noise will be gone regardless of it's source.

 

A leak there would produce a scary sound that mimics an engine knock.
I had a leak there onn my Maxim and I thought it was a Rod Bearing.

I probed the Block and couldn't hear any kind of knock during some troubleshooting listening for the knock; so I made-up an Old Fashioned Exhaust Leak finder and went looking for a leak.

Tape a small "Flag" of tissue to the end of your Probing Rod.
Look for it to flutter while you probe the Collars and Clamps.

My number three was fluttering like a Flag in on a Golf Course.
I shut her down and did a Permatex treatment to all the Donuts and stopped the leaks cold in their tracks.

Still motoring on the originals ... but, new Donuts are on the Winter Project List!

 

Cool thanks Rick - I tried the flag trick and saw no movement at the "nuts" . I did not think to probe at the lower joint. Could be it was the lower joint all the time. Hopefully it's gone on reassembly.

 

Sealant should not be necessary but I use a touch to hold the doughnut in place while I assemble everything.

 

Here is what I hope the final is:

My bike appeared to be singing a 3 part disharmony

1) slight exhaust leak in #3 doughnut
2) major exhaust leak in #2 header pipe lower clamp
3) increased valve noise since I shimed 3 tight valves looser.

The #2 header clamp was all but stripped so I put a nut behind it. Wound up assembling the doughnuts dry as they looked close to new condition. The valve noise is definitely louder than before but I am assuming this is because I shimmed them to the correct clearances. The valves were # 3 and 4 exhaust and # 4 input.

Thanks for all the advice and assistance!