How to fix a broken exhaust flange

XL777
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How to fix a broken exhaust flange

26 Aug 2009 22:38 - 26 Aug 2009 22:41

One of my exhaust flange crack in half last night from over tightening. One of my shims was out of alignment and I was in a rush to put the header back on. So like a fool I cranked too hard :blush: Is there ANY way to fix it JB weld maybe lol ??? or should I start hunting the junk yard. There is not much around Edmonont that I know of for old KZ so I may be hunting for a while

2012 Triumph Bonneville SE black

1978 KZ1000 B2 LTD
Fresh top end rebuild
Rebuilt head
Wiseco 1015 pistons
Dyna s
Green Dyna coils
Wired george mod

It is easier to say what I haven't replaced then what I have.

I must love this cruel mistress since she hates me

Last edit: 26 Aug 2009 22:41 by XL777.

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mzandmz
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Re: How to fix a broken exhaust flange

26 Aug 2009 22:46

#316681

Any one to weld it up?

New to Family, 1979 KZ440 LTD

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Old Man Rock
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Re: How to fix a broken exhaust flange

27 Aug 2009 04:21 - 27 Aug 2009 04:32

#316695

Holly crap, how much torque did you possibly use to crack (in half) an exhaust flange... :blink: Surprised your not posting how the exhaust stud ripped out of the head....

@ Z1 and they do sell individually....
www.z1enterprises.com/catalog.aspx?pid=KZ1000-A1-1977-EX0

Redline cycle, $17 per flange.... Not sure if they sell individuals but since you busted one, may want to think about the others....

www.redlinecycle.com/flanges.html

1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
MIKUNI, RS-34'S...
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az

Last edit: 27 Aug 2009 04:32 by Old Man Rock.

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BSKZ650
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Re: How to fix a broken exhaust flange

27 Aug 2009 04:44

#316700

I have snapped one before,, it dosent take much to do it either, I replaced all 4 of mine with new ones, not stock looking ,, but they seem to be a lot stonger, billet ,, not cast

77 kz650, owned for over 25 years
77 ltd1000, current rider
76 kz900, just waiting
73 z1,, gonna restore this one
piglet, leggero harley davidson
SR, Ride captian, S.E.Texas Patriot Guard Riders.. AKA KawaBob

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Old Man Rock
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Re: How to fix a broken exhaust flange

27 Aug 2009 05:27

#316705

Snapped @ 4-6 ft lbs of torque! :blink:

Wonder if the originals get brittle over time...

Either way, new ones for sure....

1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
MIKUNI, RS-34'S...
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az

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XL777
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Re: How to fix a broken exhaust flange

27 Aug 2009 07:11

#316723

Ya I way over torqued it. It was in bad shape very pitted and rusted. Plus the shim was not seated right.
I'm going to hunt some junk yards first. If I order from Z1 it will take over a week to get here and the season is too short here in Alberta to waste lol.

2012 Triumph Bonneville SE black

1978 KZ1000 B2 LTD
Fresh top end rebuild
Rebuilt head
Wiseco 1015 pistons
Dyna s
Green Dyna coils
Wired george mod

It is easier to say what I haven't replaced then what I have.

I must love this cruel mistress since she hates me

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650ed
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Re: How to fix a broken exhaust flange

27 Aug 2009 07:21

#316724

Not to preach, but another reason to use a torque wrench and manual. Aluminum is not very forgiving.

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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PLUMMEN
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Re: How to fix a broken exhaust flange

27 Aug 2009 08:28

#316736

stock flanges are cast iron not aluminum

Still recovering,some days are better than others.

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Russ Jackson
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Re: How to fix a broken exhaust flange

27 Aug 2009 09:05

#316744

XL777 wrote:

Ya I way over torqued it. It was in bad shape very pitted and rusted. Plus the shim was not seated right.
I'm going to hunt some junk yards first. If I order from Z1 it will take over a week to get here and the season is too short here in Alberta to waste lol.

Z1 ships same day so I would order one first then go looking for salvage...Russ

1976 KZ 900 B1 29 smoothbores, Kerker, Lester Mags
2008 Kawasaki Concours 14 abs

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RonKZ650
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Re: How to fix a broken exhaust flange

27 Aug 2009 10:13

#316753

They are actually aluminum, I just checked, and not all that hard to break really.

321,000 miles on KZ's that I can remember. Not going to see any more.

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PLUMMEN
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Re: How to fix a broken exhaust flange

27 Aug 2009 10:55

#316759

aluminum? :blink: all the stock ones i have are cast iron,i guess i need to dig up a magnet! :laugh:

Still recovering,some days are better than others.

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650ed
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Re: How to fix a broken exhaust flange

27 Aug 2009 18:26

#316844

I can't speak for the KZ1000, but the stock ones on the KZ650 are aluminum. I wasn't clear in my comment, but I really was thinking more about the numerous bolts and studs in the aluminum engine, forks, etc., which if overtightened can strip the aluminum threads and ruin your day (week, month). Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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