Exhaust Headers

[Fireypete]

Hello All,
I've jumped over from the 750 Sport page to seek some advice. I have a 1990 750 Sport it is a USA import to Australia, The headers are some kinda home made mess and I'm after some new ones. My measurements show the outer diameter to be 38mm. I think this was a USA thing. Would any of you learned folks know what size a Paso header is....do you think/know if they would fit the 750 Sport.?
I have been told the a 900 Sport would fit BUT the measurements are quite a bit biiger than my pipes. Would the exhaust outlet on the head be the same size across the world and just the headers different...
Cheers,
Pete

[davidrose]

The OD of my ‘88 Paso headers from the cylinder to the collector manifold looks to be about 35 mm. Your best bet is to compare part numbers. I am pretty sure that with some patience you can locate used headers. Get her running and riding!

[Hifimoto]

There are actually three versions of manifold for Paso 750. And confusingly, they all have the same SN on them:

- narrow version: 35 mm diameter (US version)
- normal / wider version with two rings attachment for cylinder head: 40 mm diameter (EU older version)
- normal / wider version with one ring attachment for cylinder head: 39,4 mm diameter (EU newer version)

[paso750]

>>.do you think/know if they would fit the 750 Sport.?

Hi,

no, they don't- It's not about the diameter but the overall shape. Below some pictures.
The first two show a SS header, which is similar to the one of the Sport. Towards the silencers it spreads outwards. The connection to the rear cylinder header tube angles steep upwards
The reason is the swingarm and shock setup.
In the 3rd pic with the silencers, the very rear ones are Paso, the others are Sport
The Paso header tubes run parallel below the frame rails and the silencers are longer and offset outwards.
Sport silencers angle inwards, therefore won't work on a Paso header.

G.