I have a problem fitting the header pipes back on.

[crash7863]

1989 FJ1200 CV3

Are all of the bends for the header pipes the same? I had to disconnect the header pipes from the collector to prevent having to pull the collector sideways to get the bolt under the collector to line up to mount the thing. Now it seems like I can't get the right side header pipe in. Soon as it's connected to the header pipe it seems to want to mount cock-eyed. Is it normal to have to pull every which way to mount the pipes up? Is that a specific order the header pipes go in?

[FJmonkey]

Look for the part numbers on the pipes, they are numbered each ending in a -1, -2, -3, -4. So -1 + = cylinder 1.

[crash7863]

Thanks for the heads up. Would you happen to know the orientation of the numbers off hand? I'm sure it's in the service manual somewhere too though.

[red]

Crash,

Each of the four header pipes have a different Part Number, so they do get installed in Part Number sequence.  From the Yamaha parts fiche:

1 PIPE, EXHAUST L 1TX-14611-00-00
2 PIPE, EXHAUST R 1TX-14621-00-00
3 PIPE, EXHAUST 3 1TX-14631-00-00
4 PIPE, EXHAUST 4 1TX-14641-00-00

#1 pipe is on the left, as you sit on the bike.  Maybe there is a Part Number stamped on each pipe, if you are lucky. 
If not, it would be a trial-and-error process to re-install the pipes.
If you install each pipe to the cylinder head, without the collector attached, it might be easier to see which pipes want to go where, at the collector end.

[crash7863]

I appreciate that. I've been trying to trial and error method. Somehow I spilled oil all over the floor and on the collector and on my face and my arms and my work pants. Oh God, this has been an unmitigated disaster. 

[red]

I appreciate that. I've been trying to trial and error method. Somehow I spilled oil all over the floor

Crash,

Kitty litter will absorb oil from the floor.  Put down 1/4" (1cm) on the oil, and walk it down smoothly.  After a few hours, sweep up the litter.
-

[Pat Conlon]

Crash, all you have left to do is to remove your clutch slave (for cleaning) then start your engine.....

It's a rite of passage. Might as well get it over with, before your final clean up.

I love it....

[FJmonkey]

Pictures or it did not happen...

[crash7863]

Oh it did happen. Found out the gasket didn't seal when I put the new oil filter it. The bike ran for 2 min just fine, then oil everywhere. Not sure if it was due to me being drunk when I did the oil change of if the gasket was the wrong size. Then when oil started pouring onto the collector, I tried to take the pipes off but they were still hot so I burned the crap out of my hands. Luckily when I did this, I had also been drinking so it did not hurt much.

[PaulG]

Strike 1

Not sure if it was due to me being drunk when I did the oil change

Strike 2

I tried to take the pipes off but they were still hot so I burned the crap out of my hands. Luckily when I did this, I had also been drinking so it did not hurt much.

Strike 3...?   

A PSA from Elmer The Safety Elephant



Actually I've never been able to find any ID/part #'s on the headers of my '92.  If there are any, where would they be located on the pipe?

[Pat Conlon]

Actually I've never been able to find any ID/part #'s on the headers of my '92.  If there are any, where would they be located on the pipe?

The numbers are stamped on each pipe on the bottom, just after the fuel/air ports where the pipe joins the collector box

[Urban_Legend]

Don't blame the alcohol.
It was really your subconsious telling you that you really wanted to pull everything off the bike for a good clean. 
Chalk it up to experience and have another drink (it dulls the pain as you said)

Mark

[balky1]

When you finally determine the correct order for the parts, this is how I put mine on:
- with the collector down, attach the pipes loosely on it
- attach the pipes to the head (also loosely), you will need to hold the whole assembly while doing this
- torque the pipes to the head
- check if you can put the bolt that holds the collector (if not, wiggle it until it fits, you have some room on the pipes to pull it out a bit if needed) and mount it loosely
- now torque the bolts that clamp the pipes to the collector
- and finally torque the collector to its mount.
Now check that any of the exhaust parts don't touch the oil pan or anything else. If they do, unscrew everything to be mounted loosely (don't take it down completely) and play with it until you are happy with results. Torque everything again from front to back in that order.
In the future, do not disassemble the pipes and the collector, it is much easier to dismount and mount everything as a single piece.

[Bezmozek]

LOL, great thread 
In desperate need of pictures of oil, drinks and burned hands
BTW on mine each downpipe has bolt down near the collector joint.
Those supposed to face inwards to the centre of bike and there are two lengths of downpipes.
I am not sure but shorter ones are cyl 1 & 4 I think 

[Pat Conlon]

Look at the numbers stamped on each pipe. The last digit is the cylinder #