ADVrider

Go Back   ADVrider > Bikes > Old's Cool
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 09-20-2012, 11:05 PM   #1
elementalg20 OP
Studly Adventurer
 
Joined: Sep 2008
Location: Melcher, Iowa
Oddometer: 771
KZ400 Mac 2-into-1 install issues

I hope I'm ok posting this here, figure it's for an old bike and maybe the best place. I'm trying to install a new mac system on an old 77' KZ400 to replace the horribly rusted out mufflers it had on it when it was bought.

I can't for the life of me figure out how the new header clamps are expected to ever be tight? Are you suppose to reuse the old collars? They don't seem to fit over the mac pipe(mac is a little too large). Also, just hit ebay and see there is supposed to be a copper or special gasket that I seem to be missing. I'll get a pair on order but I'm still a fair ways off being able to draw it down tight, a stack of washers could work but it's certainly not right and I've seen pictures of these systems on the bike.....I'm just missing something stupid and hope someone can point me in the right direction. I did hit up the kawtwin forums but that place is quite slow and I may never get an answer.

Thanks for the patience.....end rant.
__________________
2007 Victory Vegas Premium....finally I'm back on the road with another steed.

Gone...1998 Triumph Trophy 1200 2000 KTM Adventure 640, 1994 BMW R1100RS, 2002 BMW K1200RS,1999 VFR800, 1996 VFR750, 1985 Maxim X, 198x 250LTD
elementalg20 is offline   Reply With Quote
Old 09-21-2012, 07:42 AM   #2
F_Sahms
mostly paved
 
F_Sahms's Avatar
 
Joined: Mar 2012
Oddometer: 314
Photos would really help. Usually there's a collet piece that the clamps use to push the headers into the head, and the crush washers which are one-time-use.

Part Numbers 3 and 4 in this diagram:

http://www.powersportsplus.com/image.../0037/C-13.png
__________________
Life's too short.
F_Sahms is offline   Reply With Quote
Old 09-21-2012, 02:21 PM   #3
elementalg20 OP
Studly Adventurer
 
Joined: Sep 2008
Location: Melcher, Iowa
Oddometer: 771
The stock part number 3 won't fit over the new mac pipes. I do need new crush washers although I never saw them when I took it apart.
__________________
2007 Victory Vegas Premium....finally I'm back on the road with another steed.

Gone...1998 Triumph Trophy 1200 2000 KTM Adventure 640, 1994 BMW R1100RS, 2002 BMW K1200RS,1999 VFR800, 1996 VFR750, 1985 Maxim X, 198x 250LTD
elementalg20 is offline   Reply With Quote
Old 09-21-2012, 04:41 PM   #4
F_Sahms
mostly paved
 
F_Sahms's Avatar
 
Joined: Mar 2012
Oddometer: 314
Quote:
Originally Posted by elementalg20 View Post
The stock part number 3 won't fit over the new mac pipes. I do need new crush washers although I never saw them when I took it apart.
Is there a welded-on collet on the headers where the Part 3 fits on the OEM pipes? It looks like a 2-piece collet in the diagram. Are yours 1-piece?

Your old crush washers might still be in the head.

Are you sure the pipes are correct for your bike?
__________________
Life's too short.
F_Sahms is offline   Reply With Quote
Old 09-21-2012, 05:25 PM   #5
elementalg20 OP
Studly Adventurer
 
Joined: Sep 2008
Location: Melcher, Iowa
Oddometer: 771
Washers may well still be in the head.

My oem collets are just like those pictured, 2 piece design. The mac has a lip at the end of the pipe, and the bolt on clamp is the only other piece there. If the oem collets are to be reused I'll play hell fitting them over the mac pipes.

These should be the correct pipes, loose fit they seem to fit fine(well as well as mac systems seem to fit as I read around more).

Thanks for your help, hope I figure this out soon.
__________________
2007 Victory Vegas Premium....finally I'm back on the road with another steed.

Gone...1998 Triumph Trophy 1200 2000 KTM Adventure 640, 1994 BMW R1100RS, 2002 BMW K1200RS,1999 VFR800, 1996 VFR750, 1985 Maxim X, 198x 250LTD
elementalg20 is offline   Reply With Quote
Old 09-22-2012, 08:54 AM   #6
F_Sahms
mostly paved
 
F_Sahms's Avatar
 
Joined: Mar 2012
Oddometer: 314
Again, a couple of detailed photos would really help.

Good luck.
__________________
Life's too short.
F_Sahms is offline   Reply With Quote
Old 09-22-2012, 04:34 PM   #7
elementalg20 OP
Studly Adventurer
 
Joined: Sep 2008
Location: Melcher, Iowa
Oddometer: 771
Totally agree and I'll get some asap(it's away in the storage shed). My factory collets are 2 piece, but the new mac pipes are 3mm larger in O.D. than the stock pipes so using the collets won't really work as they won't fit around the pipe. It's as if mac should supply collets but I don't believe they do.
__________________
2007 Victory Vegas Premium....finally I'm back on the road with another steed.

Gone...1998 Triumph Trophy 1200 2000 KTM Adventure 640, 1994 BMW R1100RS, 2002 BMW K1200RS,1999 VFR800, 1996 VFR750, 1985 Maxim X, 198x 250LTD
elementalg20 is offline   Reply With Quote
Old 09-22-2012, 05:39 PM   #8
zap2504
Dave E.
 
Joined: Feb 2006
Location: Middletown, PA
Oddometer: 548
I don't have one (but wouldn't mind getting a good 2-1), but look at photo #4 here: http://www.armbell.com/kz400/viewtop...=&mforum=kz400
You apparently do not re-use your OEM collet/clamps but definitely need new exhaust pipe gaskets and the photo sure looks like it has plenty of room to tighten up the pipe, but it also looks like others have had your problem: http://www.armbell.com/forum/viewtop...c&mforum=kz400
zap2504 is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 07:35 PM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014