1980-81 style GS850 rusty crossover solution?

[mattd1205]

Hello GSR

been looking for a solution to bypass the crossover on the 1980-81 GS850 that almost always rusts out. Would it be possible to substitute the stock center pipes/crossover with the longer centerpipes from a 1977-1979 gs750 since those didn’t come with a crossover?

Matt

[Steve]

You could, except the pipes are different. On the '79 850 and the earlier 750s, the inner pipes are the continuous ones. On the '80/'81 850s, the outer pipes are continuous.

A very easy solution is to simply remove the rusty crossover and install two 7" sections of 1.5" exhaust pipe. This used to be available as repair sections, either 12" or 18" long at the auto parts store, but lately, I have not seen anything smaller than 1.75" pipe. I have also gone to the muffler shop and asked them to make a couple sections for me. Have one end expanded for a slip fit over the other pipe, then use a hacksaw to cut at least four slots (two cuts, perpendicular to each other). You can use all the stock gaskets and clamps to put everything back together.

I have pictures of this, but evidently Photo*ucket has taken a dislike to me (again) and is watermarking my pictures again.

.

[mattd1205]

You could, except the pipes are different. On the '79 850 and the earlier 750s, the inner pipes are the continuous ones. On the '80/'81 850s, the outer pipes are continuous.

A very easy solution is to simply remove the rusty crossover and install two 7" sections of 1.5" exhaust pipe. This used to be available as repair sections, either 12" or 18" long at the auto parts store, but lately, I have not seen anything smaller than 1.75" pipe. I have also gone to the muffler shop and asked them to make a couple sections for me. Have one end expanded for a slip fit over the other pipe, then use a hacksaw to cut at least four slots (two cuts, perpendicular to each other). You can use all the stock gaskets and clamps to put everything back together.

I have pictures of this, but evidently Photo*ucket has taken a dislike to me (again) and is watermarking my pictures again.

.

my original pipes on my 1978 GS750 had 4 headers that were independent of the mufflers. Did they switch that in ‘79? I had one long ago but can remember if they had two or 4 separate down pipes. Is it easy to get an airtight seal if you use tubing to replace the crossover?

[Steve]

Not sure about the 750, but the '79 850 pipes I got for my wife's bike have the inner pipes continuous from the head to the tip of the muffler. Only the outer pipes will slip out at the "Y".

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