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Exhaust interchange 1976-1985

Discussion in 'The Garage' started by Zip960, Feb 24, 2017.

  1. Zip960

    Zip960 XS650 Enthusiast

    IMG_6460.JPG 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
  2. littlebill31

    littlebill31 Smells of Raw Fuel

    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.
    Zip960 likes this.
  3. weekendrider

    weekendrider Iron Horse cowboy Top Contributor

    S.W. MO
    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.

    Zip960 likes this.
  4. 650Skull

    650Skull Dinosaur Lives Top Contributor

    74-79 Standards all had the same headers. 74-75 Standard Mufflers and the 76-79 Standard mufflers will interchange between the models
  5. Zip960

    Zip960 XS650 Enthusiast

    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.
  6. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    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.
    Zip960 likes this.
  7. Zip960

    Zip960 XS650 Enthusiast

  8. 5twins

    5twins XS650 Guru Top Contributor

    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.
    Zip960 likes this.
  9. YamadudeXS650C

    YamadudeXS650C Central New York XS650 XS650.com Supporter Top Contributor

    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.!


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