Topic: 550 exhaust fitment issues

[fmctm1sw]

Here's my 550 exhaust.  I'm not real excited one way or another about it but it's what I have to work with.  The main issue I have is the exhaust pipes aren't going to make a good fit into the cylinder head.  They aren't flanged out far enough where the exhaust manifold gaskets are.  If you look at the pictures, you'll see what I mean.  The pipe can nearly ft completely into the copper gasket.  I need a gasket with a wider cross section or something.  Any ideas?

[CoachDoc]

Try welding a slightly larger flange onto each header.

[dave500]

like coachdoc said,,maybe measure how wide it should be then take it to an exhaust place or similar,youll have to source some washers or something and open up the hole in them?a bit of a fiddle but easily doable with a few dollars spent,that flange is unusualy slim?

[Scott S]

 You're supposed to have split washers on there. The finned clamps press them into the head/crush washers.

[strynboen]

you are missing those  2 part spacers..to press on the flange..and weld a bigger flange on.. looks like it are just cut off..
the photo are from forum..

[fmctm1sw]

I should have mentioned this is just a mock up.  I had those half moon washers in there but I still didn't think it would make a proper seal.  Maybe I'll look at it again today.

[CBDee]

Those spacers just press the flange into the copper oring, they don't actually touch it themselves. Like everyone else has said, your going to have to widen that flange to stock width.

[luap]

you can go to a local harware store an get some big washers with the id of the exshaust an the od of the head

[strynboen]

or cut  aut of a 1 1/4 vater line...or any other tube..have not testet  for fit..and weld it on..if you not vill have the clamps off anymore...just make it so the tube goes direkt to the clamps..and drop that half moons.. its better and easyer that vay...

[TwoTired]

Are those headers from a CB400?

[fmctm1sw]

Are those headers from a CB400?

That thought crossed my mind but it was on a 550 when I got it.  I assumed the exhaust ports would be spaced differently but maybe I need to look closer.  I have a 350F head in my garage.

[lone*X]

How about stretching the header ends out to the size you want using a tail pipe expander?  They make a small expander  which should be just about right for 550's exhaust.  Measure the inside diameter of your set to make sure it will take the 1 1/8 in. expander.  Found this set on Amazon.

http://www.amazon.com/gp/product/B004GYZDQM/ref=pd_lpo_k2_dp_sr_1/177-3676237-7136449?pf_rd_m=ATVPDKIKX0DER&pf_rd_s=lpo-top-stripe-1&pf_rd_r=0WK7B1F494WNDT8R6D53&pf_rd_t=201&pf_rd_p=486539851&pf_rd_i=B000BN392M

[754]

  THEY look like Jardines.
 By looking at your situation I think it had slip in flangesthat fit partly into the pipe..but they would need welding to work. Maybe someone removed them to try to fit to another bike??  I think it would be woth the extra effort to make up something proper.

[Scott S]

  THEY look like Jardines.
 

 Mmmmm....Maybe. The NOS Jardines I have are four different pipes and the collector is on the muffler. Did they make other styles?

[754]

Are you talking 500-4..I know the 750s had diofferent looking headpipes but the mufler looked like that..and the primaries were long putting the collecter back further than some pipes.
 To the OP do all 4 pipes appear top go flat against the gasket? (other than the diameter problem)

[fmctm1sw]

To the OP do all 4 pipes appear top go flat against the gasket? (other than the diameter problem)

They do appear to go flat.  #2 looked about 1/2" off but I was able to push it against the head.  I'm laid up for a week or two after surgery so I'm kind of stuck at this point.  I found some of those felt, wire-wrapped looking exhaust gaskets that looked like they would work.  There was also some interference with the centerstand.  It was at an angle I'd never reach during with my riding habits though.

[754]

 What IK was getting at is if it is actually for that bike.
 Look at your first pic, the collector appearts to be going downhill at rear.. if that were level, it and collecter would look better.. Maybe its just hanging down due to not being clamped, and not propped up at correct height for the pic.
 1/2 inch sounds like a lot..

[fmctm1sw]

I was able to get it on.  I used a set of those cloth type gaskets that are wrapped in thin copper wire.  Kicking it over sounds like someone is pounding a drum in my garage.  Hopefully I can get it started...