Update: Definitive KZ650 installation of Delkevic 4-1 exhaust. I did it!!!!

78z1Joe
Offline
User
My man cave is my garage....
Posts: 85
Thanks: 21

Re: Removing Stock Exhausts

01 Jan 2019 18:46

Hi. If my memory is correct, basically you’ll have a left side , muffler and two down pipes, and a right side. There is a crossover (equalizer) underneath the engine and that can go with either side. Penatrating oil and be gentle, especially with the exhaust keepers and collar nuts. You don’t want to snap those studs. Save all the hardware as it may (!) be tough to replace. Also there should be copper crush rings in the exhaust ports, probably black fron the exhaust soot from 40 years. Usually advisable to replace those. Z1E has them for sure.
Good luck and keep us posted. Happy New Year too

1978 KZ 1000
1982 GS 300 training bike
Previous Rides...
75 RD 350
72 CB 500 Four
72 SL 125
71 CT 70
69 3 1/2 HP mini bike

Please Log in or Create an account to join the conversation.

Nerdy
Offline
Sustaining Member
Posts: 1065
Thanks: 418

Re: Removing Stock Exhausts

01 Jan 2019 20:25

#796036

Don't take this the wrong way, but you do any research at all before you post questions here?

General forum etiquette means you make some effort on your own before asking for help. A factory service manual would have answered your questions. Do you have a manual?

~~1979 KZ400~~ Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

The following user(s) said Thank You: Nebr_Rex, Nessism, SWest

Please Log in or Create an account to join the conversation.

Warren3200gt
Offline
User
Posts: 1566
Thanks: 787

Re: Removing Stock Exhausts

02 Jan 2019 00:55

#796042

In another thread you mentioned that you re wrapped the headers 2 months ago, so I assume you didn't remove the to do that?

Z1000J2 somewhat modified!

Please Log in or Create an account to join the conversation.

650Dude
Topic Author
Offline
Banned
Posts: 543
Thanks: 19

Re: Removing Stock Exhausts

02 Jan 2019 05:16 - 02 Jan 2019 06:07

#796044

Nerdy wrote: Don't take this the wrong way, but you do any research at all before you post questions here?

General forum etiquette means you make some effort on your own before asking for help. A factory service manual would have answered your questions. Do you have a manual?

Yes I actually DID do research and even found a few youtube videos. However the old timers in this forum have INVALUABLE information and I ALWAYS check in with them regardless of the manual instructions and whatever information I might find elsewhere. Surely, if youve been in this forum long enough, you know that lots of tips are NOT in the manual and are shared via this site.

Thanks for asking.

1977 Kawasaki KZ650B
1977 Kawasaki KZ750 Twin

Last edit: 02 Jan 2019 06:07 by 650Dude.

Please Log in or Create an account to join the conversation.

650Dude
Topic Author
Offline
Banned
Posts: 543
Thanks: 19

Re: Removing Stock Exhausts

02 Jan 2019 05:23

#796046

78z1Joe wrote: Hi. If my memory is correct, basically you’ll have a left side , muffler and two down pipes, and a right side. There is a crossover (equalizer) underneath the engine and that can go with either side. Penatrating oil and be gentle, especially with the exhaust keepers and collar nuts. You don’t want to snap those studs. Save all the hardware as it may (!) be tough to replace. Also there should be copper crush rings in the exhaust ports, probably black fron the exhaust soot from 40 years. Usually advisable to replace those. Z1E has them for sure.
Good luck and keep us posted. Happy New Year too

Thanks for this.

I actually ordered new studs and new nuts just in case. Bought them from a shop in England and they arrived in 4 days to me here in the States!!!

What i was asking is, can i simply unbolt the exhaust from the front, then the rear and then slide the whole thing out. There are varying opinions on this, some ppl saying that its better to take the the entire exhaust apart, piece by piece, which I dont want to do. Ive performed a lot of maintenance on my bikes, etc, but have NEVER changed an exhaust. Its a new challenge

1977 Kawasaki KZ650B
1977 Kawasaki KZ750 Twin

Please Log in or Create an account to join the conversation.

martin_csr
Offline
User
Posts: 8019
Thanks: 1645

Re: Removing Stock Exhausts

02 Jan 2019 05:27 - 02 Jan 2019 05:47

#796047

I don't know the best way for your bike, but I placed shipping boxes underneath the muffler system for support, unbolted the mufflers, unbolded the headers, then slide the whole thing out from under the motorcycle as a unit. I put tube socks onto the muffler ends & wrapped/taped towels around the mufflers & pipes to avoid any scratches. It's been a while, but after unbolting, I changed the size of the boxes to make maneuvering the mufflers easier.

....

1981 KZ650 Competition Sports and Road

Last edit: 02 Jan 2019 05:47 by martin_csr.

Please Log in or Create an account to join the conversation.

Nessism
Offline
Sustaining Member
Posts: 7660
Thanks: 3031

Re: Removing Stock Exhausts

02 Jan 2019 05:35

#796049

Its been a few years but I think you need to first get the system loose on the bike, both at the head pipes and the back, and then separate the halves at the crossover before you can remove the system.

Ed
Carb O-ring Kits : www.kzrider.com/forum/3-carburetor/61807...-o-ring-kits?start=0

www.kzrider.com/forum/faq-wiki/618026-new-owner-things-to-know

1981 KZ750E2
www.kzrider.com/forum/11-projects/604901...z750e-project-thread

Please Log in or Create an account to join the conversation.

martin_csr
Offline
User
Posts: 8019
Thanks: 1645

Re: Removing Stock Exhausts

02 Jan 2019 05:47

#796050

The cross-over gaskets can be kind of stuck, so it may take some twisting & pulling to separate the halves. not easily done with the mufflers on the motorcycle.

....

1981 KZ650 Competition Sports and Road

Please Log in or Create an account to join the conversation.

650Dude
Topic Author
Offline
Banned
Posts: 543
Thanks: 19

Re: Removing Stock Exhausts

02 Jan 2019 05:52

#796052

martin_csr wrote: The cross-over gaskets can be kind of stuck, so it may take some twisting & pulling to separate the halves. not easily done with the mufflers on the motorcycle.

....

Yep I think Im going to attempt top slide the whole thing out as one unit. Fingers crossed I dont have any issues. I really want to do this myself. My mechanic gave me a call, asked me what I was up to, and when I told him he said "I'll swap the exhaust for you!" Of course he means at the shop rate of $125 per hour. I want to do this myself.

1977 Kawasaki KZ650B
1977 Kawasaki KZ750 Twin

Please Log in or Create an account to join the conversation.

martin_csr
Offline
User
Posts: 8019
Thanks: 1645

Re: Removing Stock Exhausts

02 Jan 2019 06:31 - 02 Jan 2019 07:21

#796053

Place shipping boxes snugly under the muffler system. unbolt everything. then change out the boxes under the mufflers & lower the muffler ends. slide the headers forward, maneuvering them clear of the exhaust ports & place smaller boxes under the exhaust pipes. the rest should be easy. I'm pretty sure that's how I did it. I also had utility rugs under the motorcycle to prevent scratches after removing all of the boxes.

edit: be sure to unlock the steering lock in case you have to move the front wheel.

....

1981 KZ650 Competition Sports and Road

Last edit: 02 Jan 2019 07:21 by martin_csr.

Please Log in or Create an account to join the conversation.

650Dude
Topic Author
Offline
Banned
Posts: 543
Thanks: 19

Re: Removing Stock Exhausts

02 Jan 2019 07:16

#796057

martin_csr wrote: Place shipping boxes snugly under the muffler system. unbolt everything. then change out the boxes under the mufflers & lower the mufflers. slide the headers forward, maneuvering them clear of the exhaust ports & place smaller boxes under the exhaust pipes. the rest should be easy. I'm pretty sure that's how I did it. I also had utility rugs under the motorcycle to prevent scratches after removing all of the boxes.

....

Thanks so much for this. Will do!

1977 Kawasaki KZ650B
1977 Kawasaki KZ750 Twin

Please Log in or Create an account to join the conversation.

Street Fighter LTD
Offline
Moderator
TURBO, Its Better to be Blown than Injected
Posts: 4960
Thanks: 2105

Re: Removing Stock Exhausts

02 Jan 2019 08:03

#796059

Have a extra set of hands helping you.
Getting it off can require some contorting to get pipes off as a assembly .
Also make sure the bike is held steady or it may end up falling on top of you.
Dave

Original owner 78 1000 LTD
Mr Turbo Race Kit, MTC 1075 Turbo pistons by PitStop Performance , Falicon Ultra Lite Super Crank, APE everything. Les Holt @ PDM's Billet Goodies . Frame by Chuck Kurzawa @ Logghe Chassis . Deep sump 5qt oil pan. RIP Bill Hahn

Please Log in or Create an account to join the conversation.