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1984 XJ750 exhaust header question

Discussion in 'XJ Technical Chat' started by tpipilas, Oct 20, 2026 at 9:28 PM.

  1. tpipilas

    tpipilas New Member

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    Hello everybody! Thanks for reading!

    I've got a 1984 xj750 that's been shopped down to a cafè racer. This poor things exhaust header pipes have been through the ringer... repaired time after time and not repaired to well. I live in a condo so removing the gas tank and replacing the cylinder head down in the parking garage isn't exactly an option at the moment. People complain then I won't be able to do anything down there.
    The exhaust had been popping from cylinder head 2 and I know the previous owner had attempted to repair most of the cylinder head exhaust posts. I decided to remove all the exhaust pipes and see what I could do the repair them properly. They had crumbled as the guy used JB weld. Anyway, when I removed the pipe from cylinder 2, I found NO crushwasher. For sure the cause of the popping. I never would have gone into this whole exhaust system had he just not forgotten the crushwasher!. Anyway, i fixed exhaust pipe 2. Seems like 1 and 3 are good too but I'm having issues with for. I'll continue to work on it but I noticed something. I noticed after I've tightened the collars to the cylinder head, I can see the crushwashers between the exhaust pipes and the exhaust ports for cylinders 1 and 4. Is this normal?

    By the way, I think the issue is the original repairs perhaps aren't drilled straight thereby not allowing to collars to compress tightly enough against the exhaust port.
     

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