How to remove neutral switch from engine (still in bike)

The switch takes a 14mm socket, and I can't get the socket to fit up between the frame and the engine case to reach the switch. What do I need to use to get up in there? Should I just take the socket and lathe it down? I am hoping it isn't in there very tight, because it looks like if I lathe the socket down, it will be very thin, and probably not very strong any more.
Thanks
Nighttraingirl

 

Do you possibly have access to a 1/4" drive 14mm? Not easily found but it will slip in there. Another thought is to loosen the engine mounts (maybe remove a bolt or two) and leverage the engine clear of the frame just a bit. A very miserable way to do it but if you are bent on getting at it...

 

Well, I can look and see if I can find that socket. Thanks Robert. Someone else on here was telling me that they had removed the switch before, but didn't say how they accessed it. I would really like to get it out because it is leaking pretty badly, and I have a new one here waiting to be put in.
Thanks,
Nighttraingirl

 

I used needle nose pliers on my bike. The switch usually isn't in there really tight. I could be wrong though.

 

why doesn't an open end wrench work?

 

You need a Ratcheting Boxed-end Wrench.

But, consider this before you delve into the abyss.

What you take-out you have to put back in sooner of later.
If you are already handcuffed trying to get at a fitting before you remove it.

What's it going to be like when its time to put it back-in?

 

If you are replacing it simply for appearances sake, I would suggest you leave it alone. Why go through all the fuss if it is working and not leaking? I'm not sure the risk is worth the price to pay as Rick is pointing out.

 

I sure can't see any way you could fit a box end wrench in there. The switch sits back in a recess.
And to answer your question, Robert, it is leaking, and quite badly. Bad enough to coat the bottom of the engine with fresh oil after a short ride, and I don't like that the oil flings off toward the back tire. That's why I bought a new one.

 

I don't think that there's going to be a "Reach" or a "Short-cut" to replacing that Neutral Switch.

Looks like you are going to have to move the Collector.

That means a pretty strenuous fight with the exhaust pipes and collector.
Loosening the Nuts on the Collars is risky.
Don't break a stud.
Cut the Nuts off before you twist-off a stud and lament.
Rusted Bolts at the Collector inlets are going to need PB Blaster of WD-40

The Hanger Bolt will also be a challenge.
But, at least its only one.

I'm not kidding about the Exhaust Collar Nuts.
They might be no problem
They might be rusted and cold-welded solidly in place.

I don't mess with them even for a second try.
If they don't come right off ... I cut them off.

Cut them off by making an angled incision fron to back with a Dremel High Speed Cutting Wafer.
Then, with the incision made through the fastener ... Oil it and drive a cold chisel in the incision to break it right off.

The new Nut will go on with a bit of resistance ... but, there will be a stud there and not a stub needing drilling-out.

Pipes;

Rubber mallet.
Hit them left and right until you loosed them.

Hanger Bolt/

Its "Captive" but stacked on rubber shock mounting. Keep track of the position of those parts after you loosen that bolt.

 

Well we can't have that now can we? Looks like pulling the exhaust is in order. It isn't that terribly hard (provided you douse everything liberally with PB Blaster and don't break a stud). Use six point sockets to loosen everything, less risk of rounding hardware that way. Secure a can of Anti-Seize (brand of your choice) and new bolts to eliminate entry issues in the future. New exhaust gasket/doughnuts are cheap, spring for a new set. And as always, best of luck to you!

 

I have 4-1 exhaust on my bike, so it is not in the way. The problem is either the edge of the engine case, or the frame, because a socket will absolutely NOT fit up in there. (even a 1/4 drive). Maybe my engine is in the frame crooked. LOL.

 

New bolts (and gaskets) coming right up!:


EXHAUST SYSTEM PARTS:



Cylinder Head Exhaust Port Gaskets:


a9) OEM and aftermarket cylinder head Exhaust Port Ring Gasket....the thin "doughnut" ring gasket between the cylinder head and the exhaust header pipe. A very common source of leaks. You ALWAYS replace these whenever you remove your exhaust header(s). Aftermarket reproductions fit and seal just like the originals.


HCP583 OEM cylinder head Exhaust Port-to-Header pipe Ring Gasket, fits all XJ550, XJ650, XJ700, XJ750, and XJ900RK models. Each:
$ 4.25

HCP583SET4 OEM cylinder head Exhaust Port-to-Header pipe Ring Gasket, set of 4:
$ 16.00


HCP1617 Aftermarket cylinder head Exhaust Port-to-Header pipe Ring Gasket, fits all XJ550, XJ650, XJ700, XJ750, and XJ900RK models., each:
$ 2.50

HCP1617SET4 Aftermarket cylinder head Exhaust Port-to-Header pipe Ring Gasket, set of 4:
$ 9.50



HCP1253 OEM cylinder head Exhaust Port-to-Header pipe Ring Gasket, fits all XJ1100 models, each:
$ 3.50

HCP1253SET4 OEM cylinder head Exhaust Port-to-Header pipe Ring Gasket, fits all XJ1100 models, set of 4:
$ 12.50


HCP1618 Aftermarket exhaust Port-to-Headpipe Ring Gasket, fits all XJ1100 models, each:
$ 2.50

HCP1618SET4 Aftermarket exhaust Port-to-Headpipe Ring Gasket, fits all XJ1100 models, set of 4:
$ 9.50



Header Pipe Outlet to Exhaust Collector Inlet Gaskets:


a29) OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket....these thick doughnut and flange gaskets are used in various places on your exhaust system, and are a common source of leaks. You should carefully inspect and replace any worn or damaged originals whenever you remove your exhaust system components.


HCP584 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket......where each headpipe ends and joins into the collector is where you'll find these gaskets. Use 1 per pipe joint, 4 per bike. For use on all XJ550, XJ650 Seca and Turbo models, and all XJ750 models. Each:
$ 22.00

HCP584SET4 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket. Set of 4:
$ 82.00



HCP585 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket......where each headpipe ends and joins into the collector is where you'll find these gaskets. Use 1 per pipe joint, 4 per bike. For use on all XJ650 Maxim and Midnight Maxims, and all XJ700 models. Each:
$ 10.00

HCP585SET4 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket. Set of 4:
$ 36.00



HCP2621 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket......where each headpipe ends and joins into the collector is where you'll find these gaskets. Use 1 per pipe joint, 4 per bike. For use on all XJ900 models. Each:
$ 12.00

HCP2621SET4 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket. Set of 4:
$ 44.00



HCP588 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket. Use 1 per pipe joint, 4 per bike. For use on all XJ1100 models. Each:
$ 13.00

HCP588SET4 OEM exhaust system Header pipe Outlet-to-Collector Inlet Gasket. Set of 4:
$ 46.00



Exhaust Crossover Pipe Joint Gaskets:

a30) OEM exhaust system Crossover Pipe Joint Gasket....these thick doughnut gaskets are used where the left-to-right collector (XJ650 Maxim) or the left-to-right muffler can (XJ1100) crossover pipes join, and are a common source of leaks. You should carefully inspect and replace any worn or damaged originals whenever you remove your exhaust system components. Use 1 per bike.


HCP584 OEM exhaust system Crossover Pipe Joint Gasket. For use on all XJ650 Maxim and Midnight Maxim models.
$ 22.00


HCP588 OEM exhaust system Crossover Pipe Joint Gasket. For use on all XJ1100 models.
$ 13.00




Collector Box Outlet to Muffler Can Inlet Gaskets:

a30) OEM exhaust system Collector Outler-to-Muffler Can Inlet Gasket. These doughnut gaskets are used at the rear of the system collector, and joint the muffler can inlet, and are a common source of leaks. Use 1 gasket per muffler, 2 per bike. You should carefully inspect and replace any worn or damaged originals whenever you remove your exhaust system components.


HCP588 OEM exhaust system Collector Outlet-to-Muffler Can Inlet Gasket. For use on all XJ550 models, XJ650 Seca models, all XJ750 models, XJ900, and XJ1100 models. Each:
$ 13.00

HCP588SET2 OEM exhaust system Collector Outlet-to-Muffler Can Inlet Gasket. Set of 2:
$ 25.00


HCP2621 OEM exhaust system Collector Outlet-to-Muffler Can Inlet Gasket. For use on all XJ700 models. Each:
$ 12.00

HCP2621SET2 OEM exhaust system Collector Outlet-to-Muffler Can Inlet Gasket. Set of 2:
$ 23.00


HCP2624 OEM exhaust system Turbo Joint Pipe-to-Muffler Can Inlet Gasket. Where the right side turbo outlet joint pipe outlet pipe ends and joins into the right muffler can inlet is where you'll find this gasket. Use 1 gasket per bike. For use on all XJ650 Turbo models.
$ 21.00



Exhaust Collector and Can Hardware:


eh5) Original and aftermarket Exhaust System Hardware perfectly replaces the stripped, damaged, rusted or missing originals. It is always a great idea to replace these hardware items whenever you have your system apart. And as usual, PLEASE always use anti-seize compound on the threads of any exhaust system fastener during assembly!

Exhaust system hardware is listed below BY MODEL. Within each model listing, the hardware products list starts at the "beginning" of the exhaust system---meaning where the header pipes attach to the cylinder head exhaust port----and then proceed from there, more-or-less in the following order (some models vary slightly in their layour and orientation):

* the cylinder head Threaded Studs, their flanged Nuts, and the large finned, cast aluminum Ring Nut---which of course really isn't a nut at all! By the way, I can't stress just how great an idea it is to replace these flange nuts whenever you remove your original flange nuts, for whatever reason.

* the header pipe exhaust gas analysis test port Bolt and its Washer.

* the joint where the header pipe outlet fits into the collector box inlet. On most models, the pinch clamp at this joint is permanently attached to the collector box inlet, and the only replacable items are the pinch clamp Bolt and Washer. The XJ1100 models are the only ones that use replacable Pinch Clamps, in addition to the fasteners.

* the collector box attaching hardware needed to secure the collector box---and by design, to also support the weight of almost the entire exhaust system----to the frame. Varies by model, but usually consists of a Bolt that goes through the collector box, which is then insulated by rubber dampers, and which attaches via a Collar to a "u"-shaped metal Bracket. This Bracket is then attached to the bike frame via two Bolts and Washers.

It should be noted that worn insulators (dampers) in this part of your exhaust system can lead to excessive vibration (buzzing) in the system, and it is recommended that you periodically inspect them for integrity and the mounting hardware in this critical area for security and correct tightness.

Also, note that XJ650 Maxim and Midnight Maxim models, as well as XJ1100 models, do not use a "collector box" and thus there is no associated exhuast system-to-frame mounting hardware, brackets, etc. on those models.

* the joint where the collector box outlet (or equivalent) fits into the muffler inlet stub pipe. On most models, the Pinch Clamp at this joint is permanently attached to the muffler inlet stub pipe, and the only replacable items are the pinch clamp Bolt and Washer. XJ1100 models are the only ones that use replacable Pinch Clamps, in addition to the fasteners.

* finally, our tour ends at the muffler bracket-to-footrest bracket (or frame) mounting Bolt, Washer, and Nuts, as well as the rubber bumper that is mounted on the left muffler can to cushion against the centerstand while it is in the "up" position.


The prices for each piece of hardware are listed at the end of this section.


XJ550 all Maxim and Seca models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe: HCP577


- OEM header pipe gas analysis test port Bolt, use 1 per pipe: HCP2182
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe: HCP2173


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP2181
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP2537


- OEM collector (rear) to frame mounting Bolt, use 1 per bike: HCP3931
- OEM collector (rear) to frame mounting bolt Washer, use 1 per bike: HCP3946
- OEM collector (rear) to frame mounting rubber Insulator (damper), use 2 per bike: HCP2637
- OEM collector (rear) to frame mounting rubber insulator metal Collar, use 1 per bike: HCP2634


- OEM collector outlet-to-muffler inlet clamp Bolt, use 1 per muffler: HCP3925
- OEM collector outlet-to-muffler inlet clamp bolt Washer, use 1 per muffler: HCP2537


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, use 1 per side: HCP3930
- OEM muffler frame mounting bracket bolt Oval Nut, use 1 per side: HCP3942


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2640



XJ650 all Maxim and Midnight Maxim models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe, XJ650 Maxim models: HCP577
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe, XJ650 Midnight Maxim models: HCP578


- OEM header pipe gas analysis test port Bolt, use 1 per pipe, XJ650 Maxim models: HCP2182
- OEM header pipe gas analysis test port Bolt, use 1 per pipe, XJ650 Midnight Maxim models: HCP3933
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe, XJ650 Maxim models: HCP2173
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe, XJ650 Midnight Maxim models: HCP1869


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe, XJ650 Maxim models: HCP3925
- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe, XJ650 Midnight Maxim models: HCP3928
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, XJ650 Maxim models, use 1 per pipe: HCP2537
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, XJ650 Midnight Maxim models, use 1 per pipe: HCP3945


- OEM left-to-right crossover pipe clamp Bolt, XJ650 Maxim models, use 1: HCP3925
- OEM left-to-right crossover pipe clamp Bolt, XJ650 Midnight Maxim models, use 1: HCP3928
- OEM left-to-right crossover pipe clamp bolt Washer, XJ650 Maxim models, use 1: HCP2537
- OEM left-to-right crossover pipe clamp bolt Washer, XJ650 Midnight Maxim models, use 1: HCP3945


- OEM #1 and #4 header pipe outlet-to-collector inlet clamp panhead Screw, XJ650 Maxim and Midnight Maxim models, use 1 per side: HCP3926
- OEM #1 and #4 header pipe outlet-to-collector inlet clamp screw Washer, XJ650 Maxim models, use 1 per side: HCP2173
- OEM #1 and #4 header pipe outlet-to-collector inlet clamp screw Washer, XJ650 Midnight Maxim models, use 1 per side: HCP1869


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, XJ650 Maxim models, use 1 per side: HCP3930
- OEM muffler bracket-to-frame bracket mounting Flange Bolt, XJ650 Midnight Maxim models, use 1 per side: HCP3931
- OEM muffler frame mounting bracket bolt Washer, use 1 per side: HCP3946
- OEM muffler frame mounting bracket bolt Oval Nut, use 1 per side: HCP3942


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



XJ650RJ Seca models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe: HCP577


- OEM header pipe gas analysis test port Bolt, use 1 per pipe: HCP2182
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe: HCP2173


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP2181
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP2537


- OEM collector (rear) to frame bracket mounting Bolt, use 1 per bike: HCP3931
- OEM collector (rear) to frame mounting rubber Insulator (damper), use 2 per bike: HCP2637
- OEM collector (rear) to frame mounting Frame Bracket, use 1 per bike: HCP2632
- OEM collector (rear) to frame mounting rubber insulator metal Collar, use 1 per bike: HCP2635
- OEM frame bracket-to-frame mounting Bolt, use 2 per bike: HCP3925
- OEM frame bracket-to-frame mounting bolt Washer, use 2 per bike: HCP2537


- OEM collector outlet-to-muffler inlet clamp Bolt, use 1 per muffler: HCP3925
- OEM collector outlet-to-muffler inlet clamp bolt Washer, use 1 per muffler: HCP2537


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, use 1 per side: HCP3936
- OEM muffler bracket-to-frame mounting bolt Washer, use 1 per side: HCP3946
- OEM muffler bracket-to-frame mounting bolt Oval Nut, use 1 per side: HCP3942


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



XJ650 Turbo models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe: HCP578


- OEM header pipe gas analysis test port Bolt, use 1 per pipe, 1982 XJ650 Turbo models: HCP3933
- OEM header pipe gas analysis test port Bolt, use 1 per pipe, 1983 XJ650 Turbo models: HCP3935
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe, 1982 XJ650 Turbo models: HCP2173
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe, 1983 XJ650 Turbo models: HCP4108


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP2181
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP2537


- OEM collector (rear) to frame bracket mounting Bolt, use 1 per bike: HCP3931
- OEM collector (rear) to frame mounting rubber Insulator (damper), use 2 per bike: HCP2637
- OEM collector (rear) to frame mounting Frame Bracket, use 1 per bike: HCP2632
- OEM collector (rear) to frame mounting rubber insulator metal Collar, use 1 per bike: HCP2635
- OEM frame bracket-to-frame mounting Bolt, use 2 per bike: HCP3925
- OEM frame bracket-to-frame mounting bolt Washer, use 2 per bike: HCP2537


- OEM left muffler inlet flange-to-turbo outlet Bolt, XJ650 Turbo models, use 1 per bike: HCP3934
- OEM left muffler inlet flange-to-turbo outlet stud Nut, 1982 XJ650 Turbo models, use 2 per bike: HCP2617
- OEM left muffler inlet flange-to-turbo outlet stud Nut, 1983 XJ650 Turbo models, use 2 per bike: HCP3943


- OEM right muffler inlet flange-to-turbo outlet short Bolt, use 1 per bike: HCP8350
- OEM right muffler inlet flange-to-turbo outlet middle-length Bolt, use 1 per bike: HCP3925
- OEM right muffler inlet flange-to-turbo outlet long Bolt, use 1 per bike: HCP8351
- OEM right muffler inlet flange-to-turbo outlet middle-length bolt Washer, use 1 per bike: HCP2537


- OEM left muffler bracket-to-frame mounting Flange Bolt, use 1 per bike: HCP4049
- OEM right muffler bracket-to-frame front mounting Flange Bolt, use 1 per bike: HCP4956
- OEM right muffler bracket-to-frame rear mounting Flange Bolt, use 1 per bike: HCP4049
- OEM left muffler bracket-to-frame mounting bolt Nut, use 1 per side: HCP4034
- OEM right muffler-to-frame mounting bracket front bolt Nut, use 1 per side: HCP6264
- OEM right muffler-to-frame mounting bracket rear bolt Nut, use 1 per side: HCP4034


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



XJ700 all models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, all XJ700 non-X models, use 1 per pipe: HCP579
- OEM header pipe large finned, cast aluminum Ring Nut, all XJ700-X models, use 1 per pipe: HCP580


- OEM header pipe gas analysis test port Bolt, use 1 per pipe: HCP3572
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe: HCP2173


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP3928
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP3945


- OEM collector (rear) to frame bracket mounting Bolt, use 1 per bike: HCP3931
- OEM collector (rear) to frame mounting rubber Insulator (damper), use 2 per bike: HCP2637
- OEM collector (rear) to frame mounting Frame Bracket, use 1 per bike: HCP3736
- OEM collector (rear) to frame mounting rubber insulator metal Collar, use 1 per bike: HCP2635
- OEM frame bracket-to-frame mounting Bolt, use 2 per bike: HCP3925
- OEM frame bracket-to-frame mounting bolt Washer, use 2 per bike: HCP2537


- OEM collector outlet-to-muffler inlet clamp Bolt, use 1 per muffler: HCP3925
- OIEM collector outlet-to-muffler inlet clamp bolt Washer, use 1 per muffler: HCP2537


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, use 1 per side: HCP3939
- OEM muffler frame mounting bracket bolt Washer, use 1 per side: HCP3947


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



u]XJ750 all Maxim, Midnight Maxim, and Seca models:[/u]

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe: HCP579


- OEM header pipe gas analysis test port Bolt, use 1 per pipe, 1982 XJ750 Maxim and all XJ750 Seca models: HCP2182
- OEM header pipe gas analysis test port Bolt, use 1 per pipe, 1983 XJ750 Maxim and Midnight Maxim models: HCP3572
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe, XJ750 Maxim and XJ750 Seca models: HCP2173
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe, X750 Midnight Maxim models: HCP1869


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP3927
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP3945


- OEM collector (rear) to frame bracket mounting Bolt, use 1 per bike: HCP3931
- OEM collector (rear) to frame mounting rubber Insulator (damper), use 2 per bike: HCP2637
- OEM collector (rear) to frame mounting Frame Bracket, use 1 per bike: HCP2632
- OEM collector (rear) to frame mounting rubber insulator metal Collar, use 1 per bike: HCP2635
- OEM frame bracket-to-frame mounting Bolt, all XJ750 Maxim and XJ750 Seca models, use 2 per bike: HCP3925
- OEM frame bracket-to-frame mounting Bolt, all XJ750 Midnight Maxim models, use 2 per bike: HCP3928
- OEM frame bracket-to-frame mounting bolt Washer, all XJ750 Maxim and XJ750 Seca models, use 2 per bike: HCP2537
- OEM frame bracket-to-frame mounting bolt Washer, XJ750 Midnight Maxim models, use 2 per bike: HCP3945


- OEM collector outlet-to-muffler inlet clamp Bolt, all XJ750 Maxim and XJ750 Seca models, use 1 per muffler: HCP3925
- OEM collector outlet-to-muffler inlet clamp Bolt, XJ750 Midnight Maxim models, use 1 per muffler: HCP3928
- OEM collector cover-to-clamp (rear) clamp Screw, XJ750 Seca models, use 1 per muffler: HCP2264
- OEM collector cover-to-clamp (rear) clamp screw Washer, XJ750 Seca models, use 1 per muffler: HCP2173
- OEM collector outlet-to-muffler inlet clamp bolt Washer, all XJ750 Maxim and XJ750 Seca models, use 1 per muffler: HCP2537
- OEM collector outlet-to-muffler inlet clamp bolt Washer, XJ750 Midnight Maxim models, use 1 per muffler: HCP3945


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, 1982 XJ750 Maxim models, use 1 per side: HCP3931
- OEM muffler bracket-to-frame bracket mounting Flange Bolt, 1983 XJ750 Maxim and Midnight Maxim models, use 1 per side: HCP3938
- OEM muffler bracket-to-frame bracket mounting Flange Bolt, all XJ750 Seca models, use 1 per side: HCP3937
- OEM muffler bracket-to-frame mounting bolt Washer, 1982 XJ750 Maxim models, use 1 per side: HCP3946
- OEM muffler frame mounting bracket bolt Oval Nut, use 1 per side: HCP3942


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



XJ900RK Seca models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2941
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP581
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe: HCP580


- OEM collector gas analysis test port Bolt, use 1 per pipe: HCP3572
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe: HCP2173


- OEM header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP3925
- OEM header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP2537


- OEM collector (rear) to frame bracket mounting Bolt, use 1 per bike: HCP3931
- OEM collector (rear) to frame mounting rubber Insulator (damper), use 2 per bike: HCP2637
- OEM collector (rear) to frame mounting Frame Bracket, use 1 per bike: HCP2632
- OEM collector (rear) to frame mounting rubber insulator metal Collar, use 1 per bike: HCP2635
- OEM frame bracket-to-frame mounting Bolt, use 2 per bike: HCP3925
- OEM frame bracket-to-frame mounting bolt Washer, use 2 per bike: HCP2537


- OEM collector outlet-to-muffler inlet clamp Bolt, use 1 per muffler: HCP3925
- OEM collector outlet-to-muffler inlet clamp bolt Washer, use 1 per muffler: HCP2537


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, use 1 per side: HCP3929
- OEM muffler frame mounting bracket bolt Nut, use 1 per side: HCP4034


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



XJ1100 Maxim models:

- OEM cylinder head exhaust port Threaded Stud, use 2 per header pipe: HCP2942
- OEM header pipe to above stud Flange Nut, use 2 per header pipe: HCP2617
- OEM header pipe large finned, cast aluminum Ring Nut, use 1 per pipe, XJ650 Maxim models: HCP2615


- OEM header pipe gas analysis test port Bolt, use 1 per pipe: HCP2182
- OEM header pipe gas analysis test port bolt Washer, use 1 per pipe: HCP2173


- OEM #2 header pipe outlet-to-collector inlet Clamp, use 1: HCP3940
- OEM #3 header pipe outlet-to-collector inlet Clamp, use 1: HCP3941
- OEM #2 and #3 header pipe outlet-to-collector inlet clamp Bolt, use 1 per pipe: HCP3925
- OEM #2 and #3 header pipe outlet-to-collector inlet clamp bolt Washer, use 1 per pipe: HCP2537


- OEM left collector pipe outlet-to-muffler inlet Clamp, use 1: HCP3940
- OEM right collector pipe outlet-to-muffler inlet Clamp, use 1: HCP3941
- OEM collector pipe outlet-to-muffler inlet clamp Bolt, use 1 per muffler: HCP3925
- OEM collector pipe outlet-to-muffler inlet clamp bolt Washer, use 1 per muffler: HCP2537


- OEM left-to-right crossover pipe Clamp, use 1: HCP3940
- OEM left-to-right crossover pipe clamp Bolt, use 1: HCP3925
- OEM left-to-right crossover pipe clamp bolt Washer, use 1: HCP2537


- OEM #1 and #4 collector pipe chrome cover Bolt, use 2 per side: HCP3572
- OEM #1 and #4 collector pipe chrome cover bolt Washer, use 2 per side: HCP8355


- OEM muffler bracket-to-frame bracket mounting Flange Bolt, use 1 per side: HCP3931
- OEM muffler frame mounting bracket bolt Washer, use 1 per side: HCP3946
- OEM muffler frame mounting bracket bolt Oval Nut, use 1 per side: HCP3942


- OEM left side muffler rubber Bumper, for where the centerstand contacts the muffler when not being used: HCP2639



PRICES FOR EXHAUST SYSTEM HARDWARE LISTED ABOVE:

Bolts, Screws and Studs:

HCP2181 Bolt, each: $ 2.00
HCP2181SET4 Bolts, set of 4: $ 7.00

HCP2182 Bolt, each: $ 2.50
HCP2182SET4 Bolts, set of 4: $ 8.50

HCP2264 Screw, each: $ 1.50
HCP2264SET2 Screws, set of 2: $ 2.75

HCP2941 Stud, each: $ 1.50
HCP2941SET2 Studs, set of 2: $ 2.75
HCP2941SET8 Studs, set of 8: $ 11.00

HCP2942 Stud, each: $ 3.00
HCP2942SET2 Studs, set of 2: $ 5.75
HCP2942SET8 Studs, set of 8: $ 20.00

HCP3572 Bolt, each: $ 1.75
HCP3572SET4 Bolts, set of 4: $ 6.50

HCP3925 Bolt, each: $ 1.25
HCP3925SET2 Bolts, set of 2: $ 2.25
HCP3925SET4 Bolts, set of 4: $ 4.25

HCP3926 Screw, each: $ 1.00
HCP3926SET2 Screws, set of 2: $ 1.75

HCP3927 Bolt, each: $ 2.00
HCP3927SET4 Bolts, set of 4: $ 7.00

HCP3928 Bolt, each: $ 1.25
HCP3928SET2 Bolts, set of 2: $ 2.25
HCP3928SET4 Bolts, set of 4: $ 4.25

HCP3929 Bolt, each: $ 2.25
HCP3929SET2 Bolts, set of 2: $ 4.25

HCP3930 Bolt, each: $ 4.50
HCP3930SET2 Bolts, set of 2: $ 8.50

HCP3931 Bolt, each: $ 1.50
HCP3931SET2 Bolts, set of 2: $ 2.75

HCP3933 Bolt, each: $ 1.00
HCP3933SET4 Bolts, set of 4: $ 3.25

HCP3934 Bolt, each: $ 1.50

HCP3935 Bolt, each: $ 1.50
HCP3935SET4 Bolts, set of 4: $ 5.00

HCP3936 Bolt, each: $ 3.00
HCP3936SET2 Bolts, set of 2: $ 5.50

HCP3937 Bolt, each: $ 2.50
HCP3937SET2 Bolts, set of 2: $ 4.75

HCP3938 Bolt, each: $ 7.00
HCP3938SET2 Bolts, set of 2: $ 13.50

HCP3939 Bolt, each: $ 1.50
HCP3939SET2 Bolts, set of 2: $ 2.75

HCP4049 Bolt, each: $ 3.00

HCP4956 Bolt, each: $ 1.50

HCP8350 Bolt, each: $ 1.00

HCP8351 Bolt, each: $ 1.50



Washers:

HCP1869 Washer, each: $ 1.00
HCP1869SET2 Washers, set of 2: $ 1.50
HCP1869SET4 Washers, set of 4: $ 2.50

HCP2173 Washer, each: $ 1.00
HCP2173SET2 Washers, set of 2: $ 1.50
HCP2173SET4 Washers, set of 4: $ 2.50

HCP2537 Washer, each: $ 1.00
HCP2537SET2 Washers, set of 2: $ 1.50
HCP2537SET4 Washers, set of 4: $ 2.50

HCP3945 Washer, each: $ 1.00
HCP3945SET2 Washers, set of 2: $ 1.50
HCP3945SET4 Washers, set of 4: $ 2.50

HCP3946 Washer, each: $ 2.50
HCP3946SET2 Washers, set of 2: $ 4.75

HCP3947 Washer, each: $ 4.75
HCP3947SET2 Washers, set of 2: $ 9.00

HCP4108 Washer, each: $ 1.00
HCP4108SET4 Washers, set of 4: $ 3.50

HCP8355 Washer, each: $ 1.25
HCP8355SET4 Washers, set of 4: $ 4.50




Nuts and Ring Nuts:

HCP577 Ring Nut, each: $ 22.00
HCP577SET4 Ring Nuts, set of 4: $ 82.00

HCP578 Ring Nut, each: $ 17.00
HCP578SET4 Ring Nuts, set of 4: $ 64.00

HCP579 Ring Nut, each: $ 24.00
HCP579SET4 Ring Nuts, set of 4: $ 89.00

HCP580 Ring Nut, each: $ 17.50
HCP580SET4 Ring Nuts, set of 4: $ 66.00

HCP581 Flange Nut, each: $ 2.00
HCP581SET2 Flange Nuts, set of 2: $ 3.95
HCP581SET8 Flange Nuts, set of 8: $ 13.00

HCP2615 Ring Nut: no longer available

HCP2617 Nut, each: $ 4.50
HCP2617SET2 Nuts, set of 2: $ 8.00
HCP2617SET8 Nuts, set of 8: $ 29.50

HCP3942 Nut, each: $ 6.50
HCP3942SET2 Nuts, set of 2: $ 12.50

HCP3943 Nut, each: $ 5.00
HCP3943SET2 Nuts, set of 2: $ 9.50

HCP4034 Nut, each: $ 1.25
HCP4034SET2 Nuts, set o 2: $ 2.25

HCP6264 Nut, each: $ 8.50


Brackets, Clamps, Collars, Insulators, Stoppers:


HCP2632 Bracket, each: $ 36.00

HCP2634 Collar, each: $ 8.00
HCP2635 Collar, each: $ 12.00

HCP2637 Damper, each: $ 8.00
HCP2637SET2 Dampers, set of 2: $ 15.00

HCP2639 Bumper, each: $ 7.00
HCP2640 Bumper, each: $ 4.00

HCP3736 Bracket: no longer available

HCP3940 Clamp, each: $ 12.00
HCP3940SET2 Clamps, set of 2: $ 23.00
HCP3940SET3 Clamps, set of 3: $ 34.00

HCP3941 Clamp, each: $ 12.00
HCP3941SET2 Clamps, set of 2: $ 23.00

 

Have you tried to loosen up all of the engine mounts and shift the motor yet?

 

OK if anyone wants to know how to do this... I took the 14mm socket and had the outside turned down to the diameter of a 13mm socket. It worked perfectly. Leak fixed. I found another one though, will make a new post about it.

 

American ingenuity in action.
Nice bit of work there, N-T-Girl.

You get a Golden Wrench for pulling that job off!

How about taking a picture and posting it with your next reply, please!

 

Here here NightTrain! Well done. I'm looking forward to your pictures.