Exhaust

On my 82 kz440 I dropped the exhaust to clean off some rust and refinish the chrome....now I can't get them back on....is there a trick to getting them back on? I'm a 16th of an inch from being able to put the rear foot peg bolts through the exhaust and into the frame. Any advice would be appreciated. 

I would not tighten the flange area by the head fully, just get them hand/ finger tight.
Then put the exhaust where you need it by the hangers and get that set.  Then tighten everything after.

Got em back on. Has anyone ever taken the baffles out of one of these 440s? Do you need to re-jet it after doing that? Does it make a big difference in the sound of the bike? Is it worth doing? 

wrote:

Got em back on. Has anyone ever taken the baffles out of one of these 440s? Do you need to re-jet it after doing that? Does it make a big difference in the sound of the bike? Is it worth doing? 

Great idea if you enjoy being hated and annoying everyone you ride within 1/2 mile of.

I have a 81 440 A2 but have never had any problem putting the Exhaust back on the trick is to fit them loose at 1st and when all lined up tighten every thing up.
Regarding removing the Baffles not a good Idea the best way is to get a pair of downpipes and put on whatever Silencers you want. I am running mine with a 2 into 1 and a BSA Goldstar Silencer at the Moment and it runs perfectly and does not need re-jetting .
 

I removed my baffles one time years ago.
It's loud and has an annoying resonance around 6000rpm.
I replaced my stock baffle with a baffle I could pack.
Sound is much better.
Performance is about the same.

Try it without the baffle if you like.
It's a pain getting it out though.

Here's what it look like.
This is off of an 81 kz440 D2

kzrider.com/forum/2-engine/612951-silenc...hoto-kz440-81#828730