Exhaust interchange 1976-1985

Zip960

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Just bought a 1976 XS650c basket case. Doing well locating the missing parts.

On the exhaust system, I used the OEM web sites and found 1976 1977 & 1979 exhaust systems (head pipe & muffler) interchange.

MY QUESTION: what changes with 1980, 1981, 1983, exhaust systems.....what changed after 1979? What does one need to do to fit late exhaust systems on earlier model exhaust systems? Is it mounting points!

Inputs appreciated
 
The XS650 frame went from the "Standard" to full "Special" in 1980.
'79 had a Standard and Special.
I believe, others will verify, that the mounts are different.
 
The special exhaust is a one piece unit with the muffler welded to the head pipes. The standard exhaust was a two piece with the muffler using a compression gasket between the head pipe and the muffler. The mounting point on the frame is the same under the motor but the two system use different styles of brackets at the muffler. The bike in my avatar is a SJ with standard headers and aftermarket mufflers. Here is a larger pic. An SJ with standard headers (you can see the mounting point for the headers under the brake pedal), special muffler hangers, TX750 swingarm and wheels, standard tank but special side covers.

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74-79 Standards all had the same headers. 74-75 Standard Mufflers and the 76-79 Standard mufflers will interchange between the models
 
74-79 Standards all had the same headers. 74-75 Standard Mufflers and the 76-79 Standard mufflers will interchange between the models

So....74-79 OEM STANDARD headers and mufflers are interchangeable. SPECIAL HEADERS AND MUFFLERS do not interchange WITHOUT BRACKET MODIFICATION and are identified by being ONE PIECE.

IF THAT is CORRECT......that really helps.
 
Yup - that is just about correctomundo....

The 74 & 75 mufflers are different from the 76-79 mufflers - but they will bolt on as I understand it, so they ARE interchangeable. The difference is purely cosmetic as far as I can tell.
 
You may find some nice original headpipes but nice original mufflers are hard to come by. The easiest solution would be a new complete aftermarket exhaust system. Also, stock headpipes are double wall and much smaller inside than they look from the outside. They're actually a little too small for best performance. 1.5" aftermarket headpipes work and perform better.
 
View attachment 95542 Just bought a 1976 XS650c basket case. Doing well locating the missing parts.

On the exhaust system, I used the OEM web sites and found 1976 1977 & 1979 exhaust systems (head pipe & muffler) interchange.

MY QUESTION: what changes with 1980, 1981, 1983, exhaust systems.....what changed after 1979? What does one need to do to fit late exhaust systems on earlier model exhaust systems? Is it mounting points!

Inputs appreciated

I believe that I still have the original mufflers from my '76, and are in good shape. See pic.
If you are interested in them, PM me.
Good luck with the project.!

74740-16fb8048cda5c27caebcd0e8c113a1c7.jpg
 
Yup - that is just about correctomundo....

The 74 & 75 mufflers are different from the 76-79 mufflers - but they will bolt on as I understand it, so they ARE interchangeable. The difference is purely cosmetic as far as I can tell.
You must change the rear footpeg and muffler mount when you go from a 74/75 muffler from a 76/79 or vice versa.
 
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