1981 750LTD exhaust questions

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12 Aug 2017 20:43 #768893 by Troubled1
1981 750LTD exhaust questions was created by Troubled1
I have a 1981 750LTD and the exhaust is rusted on the bottom of the megaphones and the glass packing is long gone. The pipe that is supposed to come out the end is also gone.
Has anyone been successful in opening up the pipes and affecting a good repair? If not, do you think it is possible to grind the welds off, remove the factory muffler sections and install aftermarket slip on mufflers?
I have a brother that is a journeyman welder and another that is a machinist so I'm thinking this is a doable project. I really want to keep the factory look and keep the bike as quiet as possible.
I'm thinking of having the ends cut open with a plasma cutter, repairing the rust holes in the bottom and then making a new baffle and installing mounting tabs in the end of the pipe so I wouldn't have to put any holes on the outside for bolts.

1981 kz750H

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12 Aug 2017 20:51 #768894 by 650ed
Replied by 650ed on topic 1981 750LTD exhaust questions
I don't know if the internals of the KZ750 muffler are similar to those of the KZ650, but the KZ650 has quite a bit going on inside. The image below shows what I mean. Ed


1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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13 Aug 2017 04:40 #768899 by Troubled1
Replied by Troubled1 on topic 1981 750LTD exhaust questions
That looks like what is going on in my pipes. Do you know if the factory pipes had glass packing in them?

1981 kz750H

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13 Aug 2017 04:47 - 31 Aug 2017 07:12 #768900 by martin_csr
Replied by martin_csr on topic 1981 750LTD exhaust questions
Glass packing? probably not.

My RH muffler broke off completely at the weld. weld C in the pic from eebbaayy.

Here's a 750H muffler system showing one of the baffles. my muffler broke off completely w the baffle still inside of it.




Last edit: 31 Aug 2017 07:12 by martin_csr.

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13 Aug 2017 06:48 #768907 by Troubled1
Replied by Troubled1 on topic 1981 750LTD exhaust questions
I'm thinking if I ground weld c in the above image on my pipes, I could use aftermarket megaphones and keep the stock look (if I can't repair mine.

1981 kz750H

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13 Aug 2017 06:52 - 13 Aug 2017 10:07 #768908 by martin_csr
Replied by martin_csr on topic 1981 750LTD exhaust questions
The stock LH muffler has a recess for the center stand. One potential problem is that aftermarket don't have the recess & the center stand will bang against the LH muffler. Some guys modify the center stand or stop so that the stand won't hit the muffler, but doing this lowers the center stand & it could scrape the ground while turning. so not recommended.
Last edit: 13 Aug 2017 10:07 by martin_csr.

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13 Aug 2017 07:18 - 13 Aug 2017 07:24 #768911 by Troubled1
Replied by Troubled1 on topic 1981 750LTD exhaust questions
The center stand never crossed my mind. I will definitely try gutting out my factory exhaust and repair it first. If that doesn't work I may need to look into a complete 4-2 aftermarket system.

1981 kz750H
Last edit: 13 Aug 2017 07:24 by Troubled1.

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