Going back to original exhaust on Seca 550... need some help

Hey... I am going back to the original exhaust on my 550 after the PO had installed a four into one exhaust system.

Did the original exhaust have spacers in the manifold where you attach the exhaust flange to the engine? There are spacers in mine which are removable - the trouble is they keep the exhaust pipes/flanges (in my opinion) from seating properly into the manifold. Not sure if I take them out, or do I leave them in?

FYI... I was tightening the exhaust flange nuts and broke off a stud. My bolt removal kit from Canadian Tire actually worked! Stud came out without any problem...

 

There aren't spacers, but there are gaskets: http://xjbikes.com/Forums/viewtopic/t=29356.html

Your best source of a diagram is the fiche: http://www.yamahapartshouse.com/oempart ... ycle/parts

Believe me, I feel your pain. I did it twice. (See sig.)

One of the most important components of the whole system is the mount for the collector box to the frame. It consists of a pair of rubber "donuts" a spacer welded to a washer, and another big washer with a specialized bolt through the middle.

Let me know if you need pics.

 

Thanks for the information - so those gaskets do remain... not a lot of stud showing through the exhaust flange/rings. I wasn't planning on changing the gaskets though.

I guess I will be needing to pick up another stud.

My collector box has the rubber donuts and washers. It didn't have the bolt which secured it to the frame so I picked one up that fit. Wouldn't mind seeing some pictures though.

 

PM me with an email address and I'll shoot off some pics, saves me hassling with Photobucket.

REPLACE the gaskets; they're cheap and a minor leak there will make you think you're about to drop a valve.

The headpipes should fit nicely into the head; be sure there isn't an even older set of gaskets hammered in behind what you've found so far.

 

Thanks Fitz for all your help and gee whiz know how!

 

Yeah, make darn sure that you seeing aluminum all the way around, and in, the exhaust hole. the gasket is actually a copper ring that crushes into place. It's very common for subsequent ones to get installed cuz people think it fell out.....

So double-check, clean the holes, and replace with new ones.
dave