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Get old mufflers off

Discussion in 'XJ Technical Chat' started by Plumper, Jun 11, 2019.

  1. Plumper

    Plumper Member

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    What's the best way of getting mufflers off xj 750 I've loosened the clamp all the way and took the bolt out off the hanger, there pretty rusty but there not even moving at all and I'm hammering the crap out of them,
     
  2. PJC750

    PJC750 Member

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    try an oil filter ratchet at wider end of exhaust for leverage,alternate lift,then press down. Have 2nd person bang opposite end with rubber mallot, shoot some pb blaster around the joint.
     
  3. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    1. Dont' hammer the crap out if them.

    2. Penetrating oil up the joint.

    3. Twist and pull, and twist an pull, and twist and push, and repeat to free the (likely rusty) gaskets up.

    4. Be patient. They will come off.
     
  4. Plumper

    Plumper Member

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    Ok thanx
     
  5. PJC750

    PJC750 Member

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    At least I got the lube n twisting idea right, no banging Plumper
     
  6. Plumper

    Plumper Member

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    No I'm not gonna do that anymore it didn't feel right and I don't wanna brake any other part of the exhaust, I took mufflers off an 83 Honda magna and they giggled right off though maybe there was a hidden clamp or something I wasent seeing on mine but I'm just impatient I guess
     
  7. Timbox

    Timbox Well-Known Member

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    The collector side I think has three cut flanges the accept the mufflers. You can take a chisel and try to open them up a little. Don't o crazy but if you open them a little and can get enough penetrating oil in there, they will come off. If you do too much twisting and cranking on the muffler its self, it will brake at the collector to muffler connection point. Old age and rust will make it brake apart.
     
  8. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    If the mufflers are so rusted that twisting brakes them, then they are not suitable for reinstallation anyway.
    The collector is the hardest part of the exhaust system to source a replacement for. Saving it is more important than saving a muffler.
     
  9. Plumper

    Plumper Member

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    I'm not trying to save the mufflers, and I'm really not trying to brake the collector, my right side muffler has a massive hole in it at the bottom that's why I'm trying to get them off and put on those other ones, I did find where they split at the ends I pryed them open a little and sprayed oil in there gonna try again tonight to get em off
     
  10. Plumper

    Plumper Member

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    If they don't loosen up still I was gonna sawzall it off just above the clamp then make a slit with a zip disc on the remaining part and try and spread it open,
     
  11. PJC750

    PJC750 Member

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    I like it, let us know how you make out.
     
  12. lupz

    lupz New Member

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    I've had great success using Wurth Rost off on exhausts in the past.

    Just spray it on let it do its magic and wiggle off.
     
  13. XJ550H

    XJ550H Well-Known Member Premium Member

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    Plus, Ice, or Blue Ice? I see it has Teflon in it too.
     
  14. lupz

    lupz New Member

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    Just the Plus version. Seems to penetrate better than the others.
     
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  15. Colin 85 700

    Colin 85 700 Active Member

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    Heat the hell out of the muffler at the joint with a torch till its red, try to wiggle while hot then pour cold water on it, or hose it till cool to the touch. Oil, Heat a bit add Penetrating oil, wiglle.
    If it doesnt go, Repeat process untill it comes off.
    Recommend "real torches" of MAP hand torch, if you only have a hand propane torch, use 2 to heat faster.
    Or grab a map torch theyre super handy.
    Otherwise if your patient and carefull with the zip disc, so you dont put a groove in the inner pipe thats pretty quick too.
     
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  16. Plumper

    Plumper Member

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    I do have a torch and map gas, never thought of that, but now I have wd-40 and oil all over is it still a good idea to use a torch? I forgot my sawzall at work like a dumb ass so I'm gonna try again tomorrow
     
  17. Colin 85 700

    Colin 85 700 Active Member

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    Penetrating oil ist that flammable, it will flare up but blow it out. allways keep a fire extinguisher nearby anytime your using fire stuffs but you should be ok.
    A wet rag or 2 at hand is always welcome
    ..... Plus you should have water near by if your trying my method.... ;)
     
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  18. Plumper

    Plumper Member

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    So I got the old muffler off, there's another ring on the pipe that was under the clamp part it's metal with a outer shell of thin copper, it's all mangled can I cut that off to and just get another one? Is that just a muffler gasket that I can buy at an auto parts store
     
  19. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    That is the gasket, and cutting it out is fine. You won't find one at an auto parts store. Yamaha or Chacal have them, but only one of those sellers will get them to you in three days or less.
     
  20. Plumper

    Plumper Member

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    Is there something else I can use instead of that gasket? i tried to put these new mufflers on and that gasket is a little to fat, but if I cut it off they'll fit I could probably fit a thinner gasket in there
     

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