Dream exhaust options.

[Gene1000]

Thank you, Muddy.

I understand where the gasket goes inside the exhaust port of the head. However, I tried getting the old gaskets out of the exhaust ports but I find it next to impossible to do this. How do I pry the old gaskets out? Is there a special tool for this?

The diagram appears not to show the stepped half collars (flanges with raised edges?) and how they fit onto the assembly. I see only the half collars that have no raised edges and that are completely smooth.

I’m still a little puzzled about how the half collars (flanges?) are arranged and when mated to the gasket, are they supposed to partially stick out? When I attempt to mate the half flanges to the gaskets and then add the half flanges with the raised edges, the joint (#3) will not reach flush with the exhaust port.

This is frustrating because I know I’m missing something. I wish there was a video showing how to insert the exhaust pipe into the port.

Also, as I said above, the diagram does not show the position of the half flanges with the raised edges. Are they inside the joint? If this is the case, and the half-flanges with the raised edges facing the port, then the “joint” will not mate flush to the exhaust port.

I found the diagram attached on the Internet and once again it does not show the half flanges with the raised edges and where they are positioned on the pipe. Are they under the “joint”?

Sorry about the confusion. I appreciate your help.

[Muddy]

G'day Gene1000

Yes, getting the old exhaust header gaskets out can be a problem. The first thing to do is to ensure there are actually gaskets in position. I've seen guys make a real mess of the exhaust port trying to get out the "gasket" that was never there. There is no tool for the gasket removal that I'm aware of - but I'm just a backyard guy. I've used screwdrivers and prybars before - but use very carefully.

The next thing to check is that all the parts you are using are from the same model and serial number. Honda changed the design of the CA77 exhaust parts thru the life of the model. This is shown very well on the CMSNL website. CMSNL and David Silver are an excellent source of parts if needed, along with other sponsors and suppliers on this forum.

The joint and the 2 collars are a matched set and not interchangeable between different designs.

Just looking at the photo you supplied, it looks like the 2 collars may be different? They should both have a flange or both not have a flange - not one of each.

The CMSNL parts diagram shows the different designs and how they fit. Note that the "flanged" collars you have are shown on the lower diagram, including the orientation to fit. Also note that the CMSNL parts lists uses different reference numbers, but it is pretty clear on the lower diagram how they are assembled.

Hope this helps further.

Regards

Muddy

[Muddy]

Excuse the roughness and simplicity of the attached, but hopefully it shows the orientation of the components as part of assembly.