78 GL1000 Exhaust

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Lucien Harpress
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Re: 78 GL1000 Exhaust

#16

Post by Lucien Harpress »

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1980 KZ1300- Bike's Haunted
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1972 CB750- Broke the Chain And Ate the Motor
1969 CT90- The Most Fun You Can Have on 90ccs.
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Re: 78 GL1000 Exhaust

#17

Post by pidjones »

Great! Now, take a scribe or small screwdiver to MAKE SURE there are no (sometimes more than one) copper gaskets compressed and darkened up in the head exhaust ports. I once pulled six total (out of four ports) from one engine.
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Re: 78 GL1000 Exhaust

#18

Post by 5speed »

pidjones wrote: Thu Aug 04, 2022 7:20 am Great! Now, take a scribe or small screwdiver to MAKE SURE there are no (sometimes more than one) copper gaskets compressed and darkened up in the head exhaust ports. I once pulled six total (out of four ports) from one engine.
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Re: 78 GL1000 Exhaust

#19

Post by redsrback6 »

Definitely the old seals. So far, I haven't touched the big muffler. I started with the crossover piece basically soaking one end in penetrating oil while the other in some Permatex gasket removal. I'm afraid neither are doing a very good job at all. I actually have a spare crossover pipe I bought off eBay just to get the OEM clamps, but the piece was in such good shape I decided to use it rather than the piece that came with the set. Hate to admit this but I may just go back to using the original crossover piece and go with all original seals... adding a new seal to the right side where there wasn't one. This stuff is a career maker, there just ain't anything out there to make it easier. Using the 180-220 grit sanding wheels or metal sharpener stone wheel with my dremel sounds easiest but the sanding wheels evaporate in no time. Wire brush wheel may be okay in final cleanup but doesn't seem to help much at this point. I had some luck using a screwdriver or wooden tongue depressor pushing through the split ends but can't get anything going. Grabbing with needle nose pliers and rolling simply tears off till you got nothing to grab. My chisel is a bit large so I'd need to get one smaller or try a flathead, I may try it before I give up. Crazy.
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Re: 78 GL1000 Exhaust

#20

Post by 5speed »

take a hack saw blade and cut it into sections..then sacrifice a screw driver to the honda gods and use it as a chisel..
1982 1100 standard.
1986 Yamaha FJ1200
2000 Yamaha Roadstar
1976 GoldWing. running but not on the road
1978 Goldwing. future cafe project.
2019 Can-Am ryker (boss's new ride)

2002 Shadow American Classic(sold)
1983 Shadow 500. (sold)
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Re: 78 GL1000 Exhaust

#21

Post by Whiskerfish »

Make sure to wear a mask while working on those gaskets/seals. Not sure what they are made from but can't be good to breath.
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Re: 78 GL1000 Exhaust

#22

Post by redsrback6 »

Will keep that hack saw trick in mind and yes, I did break down and wore a mask after seeing some warnings. Well, I stuck with it but decided to use my smallest screwdriver. I just kept rotating around tapping on it deeper and deeper keeping the screwdriver flush till the seal finally broke loose. 2 of 3 actually came out pretty clean 1 piece, the other in 2 bands with just a little bit of the bottom sticking. Honestly, I was shocked how easy they came out. Everything I saw about soaking in liquids didn't work for me, at all. After I got em out I used a brass wire wheel followed by the 220 grit wheel to clean up, along with wiping everything down really good. Don't think I caused any damage. You guys know if the new seals just go in as is, or would you use a little bit of copper exhaust sealant?
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Lucien Harpress
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Re: 78 GL1000 Exhaust

#23

Post by Lucien Harpress »

They should be fine as-is. Truth be told, it really won't hurt anything if the muffler-to-header joints aren't 100% air-tight. Don't get me wrong, you should get them to seal as well as you're able, but at the same time they're definitely less critical compared to something like the joint between the headers and the block.
1997 Valkyrie- Light Cutomization, but Too Busy Riding
1980 KZ1300- Bike's Haunted
1976 GL1000 (Yellow)- It Runs (Poorly) and Doesn't Leak (Mostly)
1974 Velosolex 3800- Better Than Walking
1972 CB750- Broke the Chain And Ate the Motor
1969 CT90- The Most Fun You Can Have on 90ccs.
1965 CA77 Dream- Needs a Full Teardown, but Complete

All advice I give is only valid until an expert corrects me.
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Re: 78 GL1000 Exhaust

#24

Post by redsrback6 »

Thanks Lucien!!
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