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KZ440 Exhaust Header 12 Apr 2024 16:58 #897585

  • BruceinOH
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As purchased the aftermarket headers are very loose and not sealing. I scored some original finned flanges with the inserts but it does not all fit together into the header. 

I assume I am going to have to cut the “sleeves” off the headers so the original config will work?

Pics show what the stock setup would look like on the other end without the sleeve. 

Any help would appreciated. 
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KZ440 Exhaust Header 12 Apr 2024 17:02 #897586

  • Nerdy
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You have the split pieces (the collets) on backwards. The flat parts go against the cylinder head.

But yeah, the stock exhaust mounting bits won't work with that aftermarket exhaust (which was intended to use the flat flanges attached to the exhaust studs).
1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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Last edit: by Nerdy.

KZ440 Exhaust Header 12 Apr 2024 17:04 #897587

  • BruceinOH
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That was confusing as all get out. 

pic #3 shows the “sleeve” that makes the stock inserts not fit. 

pic# 2 shows the stock setup on the unflared end of the header. 

sorry for the confusion. 

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KZ440 Exhaust Header 12 Apr 2024 17:05 #897588

  • BruceinOH
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Head slap!

Thanks. 

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