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Mufflers to fit my old headers?

Discussion in 'The Garage' started by bennecc, Mar 10, 2010.

  1. bennecc

    bennecc XS650 Enthusiast

    Back when I got this basketcase the mufflers had holes rusted all through them. So I just chopped them off. Its an '81 with stock headpipes. Now that the bike is running, I'm wondering if there is a simple and cheap way to buy some mufflers and attach them to these headers??? If so what size do I need and how would I go about attaching them??

    Sorry if this is a dumb question, I'm clueless about this stuff. I'm open to any simple and cheap solutions. Thanks!!

    Attached Files:

  2. cut off the inners that are sticking out first. Then anything will work fine. Use a reducer from the inner to the new muffler.
  3. pamcopete

    pamcopete Ride.Enjoy.Life is Simple

    If the stock headers are double walled, the functional pipe is inside the outer pipe, so if you are going to use the stock headers with an after market muffler, you need an adapter that will connect the muffler to the smaller inner pipe. And, yes...the outer pipe does have drain holes in them, so if you just clamp the muffler to the outer pipe, the exhaust will leak out of the drain holes.

    The outer pipe may also leak at the head flange as well. The outer pipes were not designed to flow any exhaust, so there is no guarantee that they are gas tight from end to end.

    I used this adapter on my '81/H:


    This is a 1 1/2 X 1 3/8" adapter available at most auto supply stores, #548520. The small end will fit tightly around the outside of the inner pipe. Clamp the muffler around the large end. There is no way to clamp the small end around the inner pipe, but it fits real tight, so you can either wait for the carbon buildup to seal it or apply some Permatex muffler sealer.

    The small end is completely hidden inside the header, the big end is completely hidden inside the muffler.


    This is what it looks like when installed.

    KC 120 likes this.
  4. Pete, you have that post as a macro, admit it.
  5. chrismd

    chrismd XS650 Member

    thinking of purchasing from 650 central.com Shorty mufflers. they are 12" long i know there loud might look pretty good. the old mufflers and head-pipes have rust and corrosion. anyone know if it would be hard to change over to new stuff. i have started to work on my 78 XS650E again and decided i would like to change them.
  6. XSLeo

    XSLeo XS650 Guru Top Contributor

    Putting on new is as easy as taking the old off and slipping the new on. Some may need a bit of adapter work on the muffler mounts. Adding short straps from muffler to stock mounts.
    Just don't go to big on headpipe diameter. 1 1/2 to 1 5/8 inch pipe is plenty, 1 3/4 inch is bigger than the engine needs. It can work but needs tourque cones or some other way to keep the exhuast velocity up.
    Last edited: Jul 7, 2012
  7. chrismd

    chrismd XS650 Member

    the pipes I'm looking at are 12" long, fits 1/1/2 & 3/4. straight thru 1" core GlasPak. they do give little information order t bolt clamp for stock head pipes, after slitting. thanks for the information.
  8. XSLeo

    XSLeo XS650 Guru Top Contributor

    Those sound like mufflers to me. You might still need the adpter as Pamcopete desribes. It can be bought at most any auto parts store.
  9. gooch

    gooch XS650 Enthusiast

    im in the same boat as OP. bought a 79 xs650 special mid bob and the previous owner was just ripping everything off. where is a good place to buy some slip on mufflers?
  10. Detale

    Detale XS650 Addict

    I'd say go with the emgo shortys. Pretty much the same price everywhere. Try amazon if nothing else. I swear by them. Theyre cheap sound decent and give just enough back pressure. Also they're pretty easy to install other than slipping on theres a strap that you have to cutto size and drill a hole to mount however you want to. I have them on my rebel and the XS I can't post pics but if you look on my profile you can see what they look like. The XS has the brass finish and the reb has chrome.
  11. gooch

    gooch XS650 Enthusiast

    thanks Detale. Those look good. especially on your awesome bikes!
  12. Ive had a few different pipes on mine adn the best ones so far as far as performance would be the mikesXS reverse megaphones.
  13. jbbishop2

    jbbishop2 XS650 Enthusiast XS650.com Supporter

    Pete's adapter suggestion is also good to keep the inner pipe end secured so it's less likely to vibrate and crack. If it cracks the exhaust gets out out through those drain holes and the vent holes in the pipe up near the head.
  14. Joshuammorris

    Joshuammorris XS650 Member

    So I just bought a set of the Emgo Shorty mufflers for my 81' xs650, and was planning on using the 1 1/2 to 1 3/8" adapter that Pamcopete suggested above. My problem is that the larger end of the adapter is the same size as the small end of the muffler so it doesn't fit inside of it. How do I remedy this, or am I doing something wrong? I thought about just cutting a slit in the adapter and pinching it together, but then figured it'd make room for leaks in exhaust, or just end up collapsing together and not being of any use!
  15. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi Josh,
    pete's adapter won't work because your muffler ends are too small for his set-up.
    From the sizes you quote you need to buy 1-3/8" x 1-3/8" coupler instead.
    It'll be on the same store shelf as the adapters.
  16. Joshuammorris

    Joshuammorris XS650 Member

    Thanks a lot, man! I figured it was just something simple like that, but wanted to ask for some wisdom before I start cutting things or returning parts, haha.
  17. eagletoot

    eagletoot eagletoot

    What are some good mufflers out there that will give me a nice loud sound but nothing that will set off car alarms? I like the sound of the triumphs so thats what im trying to achieve.
  18. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi eagletoot,
    I found used Triumph mufflers went on easy and sounded fine.
    $30 the pair at a swapmeet.


    OK, they are on my XS11 but WTF, they came off a 650 twin, eh?

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