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Re: 78 GL1000 Exhaust

Posted: Wed Aug 03, 2022 10:40 pm
by Lucien Harpress
action1 action1 action1

Re: 78 GL1000 Exhaust

Posted: Thu Aug 04, 2022 7:20 am
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.

Re: 78 GL1000 Exhaust

Posted: Thu Aug 04, 2022 8:20 am
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.
:shock:

Re: 78 GL1000 Exhaust

Posted: Fri Aug 05, 2022 11:52 am
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.

Re: 78 GL1000 Exhaust

Posted: Fri Aug 05, 2022 1:26 pm
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..

Re: 78 GL1000 Exhaust

Posted: Fri Aug 05, 2022 5:51 pm
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.

Re: 78 GL1000 Exhaust

Posted: Fri Aug 05, 2022 8:10 pm
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?

Re: 78 GL1000 Exhaust

Posted: Fri Aug 05, 2022 10:18 pm
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.

Re: 78 GL1000 Exhaust

Posted: Sat Aug 06, 2022 8:33 am
by redsrback6
Thanks Lucien!!