1983 KZ400 Exaust Leak

I just replaced my exhaust pipes with a new set with very few miles on them. The problem I am having is that I just can't seem to get the cross-over pipe to seal. I had everything loose and wrapped a strap around the pipes to pull the together . Tightened the clamps around the pipes close the the ends of the outer connection. Tightened everything up and it leaks. I tried the three time and it still leaks enough to make a clicking noise when accelerating . Anyone have any tips to seal these up?

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Aha, a chance to give something back to the community from my own experience.

If you have a 4-into-1 system there will be one downpipe that crosses over the others to fit into the joining pipe. You need to 1) make sure it's properly seated all the way down into the joining pipe, and 2) use exhaust assembly paste (not the same stuff as exhaust repair paste). To make sure it's properly seated, feel and measure down the inside of the joining pipe, so that you know how far the downpipe is supposed to be seated. Then mark off that distance on the downpipe, and use a rubber mallet to knock the downpipe right into the joining section, making sure it goes in all the way.

If you're talking about where the downpipes meet the cylinder head, I have found that a certain UK exhaust manufacturer tends to supply its own single-piece exhaust collet which is significantly longer than the ones that came with the bike. These make certain pipes, though designed for a bike (and I've had this with Kawasaki and Yamahas), very difficult or impossible to fit to the head. You wonder why, until you decide to replace the rusting collets with OEM-spec half-collets, which are shorter. Hope this helps.

The OP says that the leak is in the crossover pipe, not where the pipe meets the head.

I think he needs two of these.

www.partzilla.com/product/kawasaki/11060...bdfebb454b102ae5dc92

What I linked to was for the 1983 KZ440, since there was no KZ400 sold in the U.S. at that time. I went back and looked at the 1978 KZ400 parts diagram, and it does not show any gaskets for the crossover pipe on that model, so I dunno.

It is at the crossover pipe. Some 440's had a gasket and some didn't. I have the gasket that goes in the muffler sides and it doesn't fit my style of pipe. I did get it 95% sealed though but cant test drive it as I dropped a cylinder again. Need work on that now. I used the strap again and tapped them together with a dead blow hammer. Thanks for the help though. I may look into the exhaust paste if needed.
BTW. Sorry for the typo in the header. It is a KZ440 not a 400. I wish I could get my profile to accept a signature line.

Maybe some pictures would help us sort it out.

Here are a couple of pictures from my old pipes. Maybe making sure the gap in the clamp is not over a notch might help.

If there are no gaskets & gaskets can't be fitted, I guess you could use a high temp rtv silicone sealant. I kind of wonder why Kawasaki wouldn't use gaskets on some models. maybe to allow condensation to drain? wild guess. Or maybe when new, the fit was plenty tight. ???

When installing a 750E muffler system to my 650, I used Permatex ultra copper red on the header pipes >> in case the system did fit exactly the same as the stock mufflers. I installed new gaskets, but used the sealant as a just in case. just a little. You can gob it on since it will be unseen underneath the motorcycle.

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If yours is similar to the pictures above, the crossover pipe should fit snugly in each side, and be long enough to go past the clamping cutouts on both sides. If that is not the case, maybe somebody replaced the original pipe with an incorrect one. A muffler shop should be able to fix you up with a correct piece.

Same exhaust. The pipe is snug but you can only tighten the clamps bolts so tight or you will strip it out or break the bolt . I have done both now. I may try some sealer on it although I have the feeling that in such a tight space I will probably seal myself more that the pipe.

You need the right clamps and some Gun Gum sealant.