exhaust split collar question

im kind of stumped about how these things go back on, any pictures or instructions are appreciated.

The larger end of the flange goes out. It helps to use some scotch tape to hold them together around the pipe. Also don't forget to put the flanges on the pipe before you tape them together.

ok thanx, for some reason i thought they went in the exhaust port after the copper ones. Thanx

Nick

Gringo's right with the tape idea. The tape will just burn off and you won't be throwing those nasty collars across the garage! Without tape it's a real PITA!! Just make sure that the large end fits into the groove in the collars as you tightend them up!

rubber bands also work.spraying down the copper gaskets with something like copper coat also helps hold them in place while installing header;)

PLUMMEN wrote:

rubber bands also work.spraying down the copper gaskets with something like copper coat also helps hold them in place while installing header;)

Yeah, for the copper gaskets, I've always just used a small glob of grease to hold them in place.

Col. Kilgore wrote:

Rubber bands also work. Smells like . . . Victory!

:laugh:

NickW900LTD wrote:

im kind of stumped about how these things go back on, any pictures or instructions are appreciated.

Would always use new copper crush gaskets.

Usually the split collars are okay to reinstall (after cleaning with wire brush).

My preferred procedure for reinstalling the headers is to first carefully clean the engine exhaust port recess areas with q-tips and acetone, and use a little Permatex hi-temp on new copper crush gaskets.

Put the new gaskets into place and the thin coating of Permatex holds it handily in place. Allow the Permatex to set up a little, and it's okay to put another thin coating of Permatex on outside surface of gasket.

With gaskets holding in place inside the exhaust ports, it's then much easier to manipulate the split collars and clamps into position (even without masking tape or rubber bands on the split collars) and not having the gaskets, collar halves and clamps all escaping and falling all over the place.

So with exhaust clamps hanging loosely around header pipes and new copper gaskets fitted inside the head recesses with a dab of hi-temp sealant holding them in position, hold the headers in place on the head against the gaskets. Fit a pair of split collars onto each header pipe with the small non-flared end pointing toward the engine to press against the flared ends of the header pipes. If preferred, may also use masking tape or rubber bands to hold the split collars in place during assembly.

The flared ends of the split collars fit into recesses in the exhaust clamps. The un-flared ends of the split collars fit against the flared ends of the header pipes.

While holding everything in position, loosley start the clamp holder nuts onto the exhaust studs, and assure all parts being properly fitted and aligned before tightening the exhaust stud nuts against the collars.

Clamps press against split collars.

Split collars press against header flanges.

Header flanges press against copper gaskets.

Good luck with the installation.

Patton, I've never had the pipes off my KZ650 and I always wondered how they were held in place. Thanks to your very clear description I now know. Thanks! Ed

Could post a nice pic of installation if the damn Kawasaki.com site was working!!

Got one here if you still need it....Never mind, I had it set at 500 pixels wide but it keeps saying too large (550 max) Don't know whats going on.... sorry

Post edited by: Bluemeanie, at: 2008/01/27 12:40

Post edited by: Bluemeanie, at: 2008/01/27 12:42

Almost 13 years after this post went up, and I'm SO GLAD it's here. Y'all will forever be in my thanks for this forum, and specifically thank you to Patton for this wonderfully detailed description!

Got a good looking set of original exhausts off Ebay and just got the collars, clamps, and crush gaskets delivered today! Can't wait to get rid of the rusted to hell 4-1 that's on her now