re: kz750 ltd h2 1981 - oem exhaust problem

hi y'all.

greetings from across the pond.

i've just found out that a uk based
bike shop called dk motorcycles has
been buying containers full of classic
bikes from the usa. do a search on
ebay.co.uk 'twowheelspares' and there
are many usa kaws on there.

i found an oem kaw. 4-2 exhaust system.
i've never fitted a solid exhaust like this before.
only the separate headers, linking pipes and
mufflers.

i'm really struggling to fit it.
i preassembled the crossover pipe on
the left side and managed to put this on.
i then attempted to join the right side crossover
pipe. i couldn't do this. i balanced the right
muffler on a small plastic box.

there must be a correct procedure to
assembling this.

q) would it be better to assembly
the left side to the crossover pipe,
then attach and wrench together the right side.
using the help of another person, place the
assembled exhaust under the bike, on cardboard
to stop chrome scratching.

then put the headers in place with collettes
and alu clamps. then attach mufflers to hangers.

is this the best way to install the kaw oem
4-2 exhaust system kzr's?

many thanks for your advice.

regards

angel

Angel,
I don't know if it is the best way, but that's how I've done it. get the left and right head pipes and crossover assembled, but loose at the crossover clamps. Then get it onto the engine, all 4 exhaust pipes started at the head. Again leave it loose enough for adjusting, don't tighten down on the gaskets yet. Then put the left and right mufflers on, and get them hanging at their mounts. Once everything is together, you can start getting things tight. A bit at a time so everything lines up well. then a final tightening. Run Eric, and check for leaks.

delete

hi motorhead!

long time no speak!
many thanks for your reply!

i'd to return the new motad 4-2 exhaust
system. it wouldn't intergrate with the main
stand. i phoned a company in staffordshire,
uk who advised me that they've an oem
kaw 4-2 system, a bit marked, but oem!
it cost me £160 brit pounds, a bargain if it
still works? i've never heard an oem
system fire up. my new neighbours are
very gentle elderly folks, so fingers crossed
on the db's!

i'll let you know how eric sounds.
the factory main jets have now been found.
someone must of been running pods.
the main jets were all #70, instead of #64.
all changed now and everthing factory settings.

just noticed the exhaust bores are double
skinned and narrower than aftermarket systems.
this will be better, won't it, more back pressure?

i'll let you know how eric runs and sounds motorhead!

many thanks.

angel

hi martin

many thanks also for helping
me with hints and tips of assembling this oem exhaust.
this is the first time i've seen an exhaust
system like this. i don't have a bike lift.
i've lie under the bike, with a compatible
friend to help me, you get the giggles
in situations like this, don't you.
talk about a learning curve.

i will try yours and motorheads hints & tips
thursday, fingers crossed!

i'll let you know how i get on martin!

kind regards

angel