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Exhaust Questions & Answers

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My muffler chamber has rusted but I would like to not spend to much money. Should I replace it with new, big money? or replace the entire system with a Jardine system, cheaper? Do you have to remove the engine to pull out the rear down tubes or the rear mono-shock? Thanks,

Dave Fial
1984 Venture Royale

Answer: Scott MacMartin

I have done this very job on my 1984 Venture. I like the appearance of the original exhaust, and the sound too. That is why I did not go with aftermarket parts. I purchased new pipes.

The muffler chamber under the engine can be removed without removing any other parts (other than exhaust parts). You will have to undo the pipes at the front, with the appropriate allen key, and slide them out from the chamber. The rear connection is just above the resonator, and it is a little difficult to get a wrench onto the bolt. If you find it impossible to reach, then you can undo the flange bolts 2 inches from the rear engine exhaust (they are allen bolts too) and drop the exhaust a couple of inches. If you do this, you will HAVE to buy the new seals, or the system will have a leaky sound when reassembled. THis perhaps sounds too complicated, but if you work carefully and slowly, you can accomplish this without too much time lost.

I hope that the attached web site pages will be of help.

.........Scott MacMartin Ottawa, Canada

Rear Exhaust Clamp Fix

I changed the rear cylinder exhaust gaskets a couple of times on my 83, but they never lasted for more than a year. Then I noticed that the clamps were constructed so that they included a stop to prevent over tightning, and I felt that they weren't allowing enough clamping force.
I walked over to the grinder and "adjusted" the stop, and the gaskets have lasted since (12-13 years?). In fact, when I put everything back together after fixing 2nd gear this year, I re-used the old gaskets and they sealed.

Frank (83).

Exhaust Collector Can Fix

The exhaust collector can be repaired by a competent welding shop. If you are using unleaded gasoline, the collector should last almost indefinitely. If it has a hole in it, it is also likely that the internal baffles are loose. If so, cut a trap door in the collector and remove the loose baffles. To remove the collector, first remove the front two exhaust pipes. Then remove the rear mufflers. Then loosen the two lowest exhaust clamps which clamp the rear exhaust pipes to the collector. There are two hidden 12mm bolts which bolt the collector to the motor sump. Remove them. Now you must remove the collector downward. It is likely that the exhaust pipes are rust-frozen into the collector. Spray liberal amounts of WD-40, Kroil Oil or any rust penetrant at the joint. Allow to soak overnight. Gently tap with a hammer downward. Eventually, it will loosen. It is just as difficult to reinstall the collector because the angle to the exhaust pipes has to be perfect. Advise resting the collector on a floor jack, and gradually raising it to place. Also,advise new exhaust gaskets for the rear pipes. This is "Dummadagarbei"!! (sp?)

Rey Kirkman

Collector Can Notes

The '99 New Venture has no collector or crossover pipe between the left and right side cylinders.
Consider this. Yamaha is one of the foremost designers of intake and exhaust systems. Ford used Yamaha to design the SHO Taurus intake tract, and Toyota used Yamaha to design intake tract of the new Celica. The Venture exhaust system was designed sometime before 1983. It was contemporary technology for 1982. They were competing directly for Honda Goldwing business. Silence was an objective. If you look at the stock intake and exhaust system you can easily see the efforts directed towards intake/exhaust silence. There are trade-offs with such design; and the obvious trade-off is reduced power.
The collector design was inhibited by available space. The "baffles" in the collector are not true baffles which change gas direction. They are merely perforated metal sheets spot welded to the wall of the collector. As a general rule, the larger the collector/muffler the easier it is to silence exhaust without reduced performance . Even with the small collector, for some reason Yamaha made it effectively smaller by bringing the entrance pipes and exhaust pipes well into the collector past its interior wall.
This may have the effect of slowing down exhaust gas flow, which ultimately reduces sound. Another restriction is upstream of the collector where the header pipes neck down. If you feel inside the neck you will see a ledge where the smaller pipe meets the larger pipe. This ledge causes turbulence, which decreases exhaust velocity. Any efforts to reduce these restrictions will increase sound. Heli Manufacturing has produced a modified collector for the Gold Wing with good results, both with power and acceptable noise levels. To design and manufacture a more efficient exhaust collector for the Venture will take some patience and skill. If the First Generation Venture was still in production, there might be an incentive for someone like Heli to design a less restrictive exhaust for the market.
My sense is that your idea is on the right track, but its execution may be difficult. I am sort of working on the same idea. My thought is that the geometry of the six pipes meeting together is very precise. A little off and it will not fit together and/or welds will break through stress. Therefore, it seems to me that one should use the basic collector as a "jig" to form new pipes. The problem as I see it at this time is space. The rear header pipes must make some very sharp bends to become parallel with the front header pipes. I can easily see using space below the collector, reducing valuable ground clearance.

Rey Kirkman

Last update: 11:18 PM Friday, January 6, 2006

1st Gen Exhaust Collector Repair

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