Anyone know where I can look to find a new 81 KZ440 exhaust? I just acquired a near mint 81 440. The only things wrong with it are a giant scratch on the tank (I'll respray) and the exhaust has rust holes on the bottom of it. I'm having trouble finding a replacement exhaust. I'd like a stock one in great condition, or some aftermarket. eBay seems useless, there's nothing good there last time I cheked. I'm finding a lot of mufflers, but I'm not sure how I'd be able to install them since the exhaust system has a strange cross over pipe in the middle. I'm totally new to "vintage" bikes and would certainly appreciate any help that anyone could provide.
For practical purposes, just import the downpipes from a good condition used exhaust system, from Germany. Ebay. I don't know why, but they had a lot of KZ440s in Germany. Then, when it arrives, fit whichever mufflers you prefer. You need exhaust assembly paste at the joining pipe and at the point where the exhaust connects with the mufflers.
As far as I can tell, for the purposes of exhaust fitting, the main difference between the European KZ440s and others is that the European cylinder heads have shorter exhaust bolts tham the American and UK ones. I mean, the bolts that actually fix the exhaust system to the head. The UK KZ440s are just like the American ones for the purposes of exhaust fitment, even though all the KZ440s sold in the UK were rated for 41 hp, whereas some but not all of the American ones were rated for 23-ish hp (probably super-lean Cali versions). However, you may not be able to find a KZ440 exhaust system in the UK.
The exhaust joining pipe system does seem to matter, pertaining to where the engine will produce the most power.
H-type balancing system vs Y-type balancing system. The original ones were H-type joining/balancing systems.
I’m very pleased with the amount of help I’ve already received on my first post to this forum. I hope I will find this forum to be just as helpful in the future and I hope to become a good contributing member.
Are there any posts of people purchasing clamp on mufflers and sawing off the oem mufflers for the 440? Seems like there would be some consideration as to where to cut off the muffler from the header. I’m alright with not keeping the bike completely stock since it seems like it’ll be impossible to get a NOS exhaust - or even anything clean enough to buy.
Assuming your header pipes & crossover aren't shot, you could cut off the mufflers & install new aftermarket.
Z1Enterprises.com has a variety of ss & chrome mufflers. Click the link at the top of this page, then select your motorcycle.
Helix racing has various universal mufflers. not sure if Z1Ent sells their stuff.
Whatever you get, you'll need to figure out where to make the cuts & what muffler length to get. many of the new ones may be too long. probably make the cuts at or before a weld.