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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 15 May 2010
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XT600 downpipes

I recently bought some Motad stainless steel downpipes for my '02 XT600E but they don't fit! Its too late to send them back (bought them on the web). Anyone else had the same problem? What's the best way forward, I'd like to replace the studs while I'm at it so maybe make some spacers or modify (bend) the new pipes if poss. Any ideas?
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Old 15 May 2010
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I bought the Devil downpipes (from Kedo) as they are made from 3 pieces and can easily give it a twist/bend

Guess you'll have to make them fit as you can.....

Do you really need to replace the studs?


Vando
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Old 15 May 2010
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Sometimes you have to use a bit of brute force and ignorance to make headers fit.
Aftermarket gear is like that...
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Old 16 May 2010
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hi there i have a 1985 43f xt600 and bought a set of motad headers about 18 months ago and the fit was spot on , i removed them about 6 weeks ago to clean them and to re copperslip the nuts/ studs/flange etc and they came off and went back on perfectly. i would ring motad direct and explain the situation , have you still got a reciept or proof of purchaise , ive heard of some on xts with a bad fit but im sure a bad one slips through now and again so motad should sort it , no manufacter wants a bad reputation and should be more than happy to sort it, i think this is your best course of action dont try and fourse them on it will all end in tears . zigzag
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Old 17 May 2010
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Got the same problem with my Motad Downpipe ...had to work around to make them fit!!! on mx xt 600 e

As for the stud....not as painful as I thought, you can soak them will wd 40 overnight..usually if they are very rusty the bolt are sealed to them so they should come with the bolt, if not just srew 2 more bolt on them using the second one to unscrew the whole thing...good luck hope I'm clear??

gwel
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Old 18 May 2010
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Removing the header studs on an XT600 should be routine maintenance otherwise they sieze up and snap when taking the nuts off.

They're stupidly thin and corrode faster than any i've seen.

Take them out, replace them if they look rotten. Don't forget the copperslip.
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Old 18 May 2010
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Well mine i just wire-brush them and put some high temperature Teflon that i use in my boats outboard engines and put in some new nuts every 3-4 years and they are in mint condition....


Vando
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Old 22 May 2010
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Quote:
Originally Posted by bogweasel View Post
I recently bought some Motad stainless steel downpipes for my '02 XT600E but they don't fit! Its too late to send them back (bought them on the web). Anyone else had the same problem? What's the best way forward, I'd like to replace the studs while I'm at it so maybe make some spacers or modify (bend) the new pipes if poss. Any ideas?
the headers do warp when welded if its just the gap between the head ports it can be adjusted either way a ratchet strap will tighten the gap or a wedge of wood can be used to widen the gap once they have been through a few cycles of hot and cold from normal riding use they will be fine
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