Honda Twins banner

Questions about reinstalling original exhaust (gaskets, lips, clamps, tabs, etc.)

714 views 4 replies 3 participants last post by  brian450  
#1 ·
Hi all. I'm in the process of reinstalling the original exhaust system (pipes, collector box, and mufflers) on an '85 Nighthawk 450 and just want to confirm some things before tightening everything down. I've attached a marked up picture of the exhaust system so when I say "lip" and "tabs" it's (hopefully) clear what I'm referring to.

Where the front pipe fits into the collector box, the pipe has a little lip on it. I'm assuming I want this lip to be outside of the tabs on the collector box, so when I tighten the clamp down around the tabs of the collector box, it's able to tighten onto the new gasket. Is this correct?

I have pretty much the same question for the rear mufflers, but I'm slightly more confused in this case. I was also assuming that I want the lip on the muffler (it's kind of a rounded bump, whereas on the front pipes its edges are squared off) to be outside of the tabs for the same reason, but the openings at the rear of the collector box seem much larger and it's super easy just to slide the muffler right into the opening, way past the point of the lip being inside the tabs. So, how far are the rear mufflers supposed to be inserted into the collector?

I can take some photos of the actual parts if that's helpful in clarifying what I'm trying to ask here.
 

Attachments

#3 ·
Thanks. I think I understand this much. It's just a matter of how far the front pipes and mufflers actually should be inserted into the collector. There's room for me to insert them so that the tabs go over (outside) the lips on the front pipes and the muffers, but I'm worried this will prevent the clamps from squeezing the tabs down sufficiently.
 
#4 ·
The clamps should be outside those lips, they serve to make sure the system cannot separate in any manner until the clamp is removed. Motorcycle mufflers are notorious for going loose and this is Honda's solution.
 
#5 ·
Got it. I have the original clamps for the front of the collector (aka power chamber? I can't figure out what to call that thing) so those went on nicely and should hold the front pipes in. For the rear, I don't have the original clamps anymore (when I bought the bike it had straight pipes on it and it sounded awful; I'm going to have to verify a previous owner didn't re-jet the carbs or anything one of these days...). I think they went on OK though. I torqued the nuts that secure the side of the exhaust pretty good, and the clamps as well, so hopefully won't lose one of them :). I haven't started it back up yet but will check for leaks then. Thanks for the insight folks!