Standard header measurements, help me out?

[4130coffs]

Hey Matt
just read one of your posts where you said you might weld the header clamps on to get it to seal
Got nothing against you welding them but when you R & R these things its handy to be able to turn the clamps to clear the down tubes on the frame.........just say'n

Yeah that could be an issue - i haven't looked super closely into it. The exhaust i have separates into four individual header pipes from the 4-1 collector, so that might alleviate.
Still though, it wouldn't be the first exhaust i hack to pieces... 

[Jonesy :-)]

Hey Matt
just read one of your posts where you said you might weld the header clamps on to get it to seal
Got nothing against you welding them but when you R & R these things its handy to be able to turn the clamps to clear the down tubes on the frame.........just say'n

[4130coffs]

no mate, no other bolts required, you use the original filter housing bolt and remove the big hex headed (27mm from memory) bush that holds the cooler hose adaptor block in place. All will be revealed when you remove the filter.
And definitely not a silly question.

That's excellent news! I'll have a look at this next week, cheers! I bet it looks a lot nicer without that dirty old cooler! Plus, less that can go wrong! 

[Jonesy :-)]

no mate, no other bolts required, you use the original filter housing bolt and remove the big hex headed (27mm from memory) bush that holds the cooler hose adaptor block in place. All will be revealed when you remove the filter.
And definitely not a silly question.

[4130coffs]

yeah ditched mine.....what this US sized bolt your talking about?

The oil filter housing bolt. I was reading the thread about it;

Hey guys, wouldn't it be easier just to remove the filter housing and ditch the oil filter line adapter which is an extra piece between the filter housing and the oil pan? You'd just have to get the shorter oil filter housing bolt (US spec) and put it directly onto the sump.
This way, you'd get rid of all the unwanted pipe fittings and tidy up the whole area.
Personally, I'm going to keep mine as it's that bit of extra insurance for those really extra hot days on the road.

Did you not end up needing a shorter bolt at all? (I haven't pulled it off and had a look yet, so forgive me if this is a stupid question)

[Jonesy :-)]

yeah ditched mine.....what this US sized bolt your talking about?

[4130coffs]

Hey Matt
I've got 3 systems (2 off 4 into 1's  and an original) and they all come in at 38.0 -38.5 mm diameter at the head, sorry cant help with other dimensions although in saying that the clamp plates on 2 of the systems are only about 6-8mm thick the other original header clamps are like your picture of the finned one.
Not sure if your interested, but......
All the systems retain oil cooler and centre stand.
the original system gives access to the oil filter but sump cant be removed.
The other aftermarket systems allow the removal of sump without being removed
--------------------------------------------------------------------------------------------------
EDIT
If your going for a minimal café look these things will happily run with the cooler removed, which will allow the fitment of a MAC 4-2 system

Awesome Jonezy! That clears that up. Thanks mate!

I've "modified" my plans slightly to getting the bike built and running with the parts i have std or not (mainly to make a blueslip easier). Once i have the blue i'll tear it down and build it properly - so at this stage i'm just making sure i'm not choking the thing with a totally wrong sized header pipe. I'll make these work (even if i have to weld the flanges on to seal) and depending on performance, i'll look into a new/replacement system later on.

I'll most likely be ditching the cooler - i'm just looking around the net for that US sized bolt. You've removed yours, yeah?

[Jonesy :-)]

Hey Matt
I've got 3 systems (2 off 4 into 1's  and an original) and they all come in at 38.0 -38.5 mm diameter at the head, sorry cant help with other dimensions although in saying that the clamp plates on 2 of the systems are only about 6-8mm thick the other original header clamps are like your picture of the finned one.
Not sure if your interested, but......
All the systems retain oil cooler and centre stand.
the original system gives access to the oil filter but sump cant be removed.
The other aftermarket systems allow the removal of sump without being removed
--------------------------------------------------------------------------------------------------
EDIT
If your going for a minimal café look these things will happily run with the cooler removed, which will allow the fitment of a MAC 4-2 system

[4130coffs]

Thanks everyone for the input, it's appreciated.

But let's not get too far off topic, i'm really just after some comparative measurements from a standard header, most importantly diameter.

Cheers

[pgnz]

Any 4-1 giving crappy low and midrange performance will be a poor design,  no surprise there's plenty of worthless junk out there,  I once had one like that on my XS11 and it was basically a dog.   Replaced with a real-deal cycleworks 4-1,  there's night and day difference with a properly designed outfit,  a whole heap of extra power and oodles of torque from off-idle to redline and truly enough kick to slip your clutch if it ain't beefed-up to compensate,  ain't no comparison between a "cheapo" and a "kosher" exhaust

[excess.11]

For a more even power curve to suit everyday riding along with the traditional café racer look a 4 into 2 comes to mind.
A four into one delivers better top end but a sluggish low to mid range.....which is a pita.
Just my opinion.....also my experience as I have both .
On choosing or designing an exhaust...........you will need to visit the often debated and divided opinion of .........
" Will you be able to retain the oil cooler and.......... access to the oil filter.........as well as whether or not the centre stand stays or goes " .
Use the " search tab at the top of the home page first.....as these topics have been covered previously in the past ...........this will give you more info on issues you may encounter and have nt yet considered.

[4130coffs]

Hi Matt,

The first thing I looked at when I went around to see the bike was the exhaust.

You don't have standard headers or even XS1100 headers.  They are of unknown origin.

What type of system are you after?

4-2? or 4-1?

Loud,

Standard systems are as rare as rocking horse shit.

Let us know

Eddy

Hi Eddy. I'm happier with a 4-1 setup. Good to know this isn't std for sure, i didn't think it was.

Still would be helpful to get a few measurements to ascertain whether I bother modifying these to fit & seal or find another solution.

I'm especially curious about the header diameter.

[XSIIE]

Hi Matt,

The first thing I looked at when I went around to see the bike was the exhaust.

You don't have standard headers or even XS1100 headers.  They are of unknown origin.

What type of system are you after?

4-2? or 4-1?

Loud,

Standard systems are as rare as rocking horse shit.

Let us know

Eddy

[BrettS]

An overall picture of what you have could be helpfull

[excess.11]

Hi Matt.....me again........
Easiest way to tell if you have the original headers...........take a look in side the ends..........are they single or double walled ?
The pics shown seem to indicate aftermarket.
Double walled = Original...........Single walled = After market.