Exhaust header leak

[MoPar]

Hello, I have an 82 GS1100L that I foolishly took the exhaust off of to remove the rear wheel/swing arm to replace the output gears on the trans. I have it all back together however, the inbored headers leak badly. I made sure to evenly space the 2-piece rings, and to tighten the flanges first b4 anything else, as well as retighten them once motor was hot. I just cant seem to get a good seal :\. Any ideas? Thanks

[Frank Z.]

Made sure your exhaust gaskets were in place and in good condition prior to install??

[sedelen]

Sounds like you need new seals/gaskets.
Those things are fragile at best and once crushed they just may not reseal properly. If all else fails after you retighten them like you said I'd replace them.
Item 3 on this fische, $4.24 each at Boulevard Suzuki.

http://www.boulevardsuzuki.com/fiche_section_detail.asp?section=96179&category=Motorcycles&make=SUZUKI&year=1982&fveh=2159

[MoPar]

Well I replaced the gaskets and it still leaks

[Nessism]

You have to play with it. Loosen all the bolts on the entire system and make sure the head pipes are inserted all the way into the ports and are not hanging up anywhere. Shake the system within the bolt play, mufflers included and shove the headers in before trying to tighten them up. If it was on before and not leaking, it can be again.

[MoPar]

You have to play with it. Loosen all the bolts on the entire system and make sure the head pipes are inserted all the way into the ports and are not hanging up anywhere. Shake the system within the bolt play, mufflers included and shove the headers in before trying to tighten them up. If it was on before and not leaking, it can be again.

I'll give it another try :/... 3rd time will hopefully be a charm. It needs to cool off though, its still 95 @ 9pm :P.

[7981GS]

Place a small bead of Ultra Copper or Ultra Black Gasket Maker around the sealing flanges before installation and they will be better than new.
If you only have red RTV, that will work also but allow it to dry over-night after you tighten the bolts/nuts whichever you are using to attach the head pipes to the head.
And as Ed said, make sure that the tubes go ALL the way into the head before tightening.

Eric

[MoPar]

Wow, I'm ashamed to even admit this, but I figure I should incase someone has the same problem lol. The shoulder of the half-rings need to face outward :\. I had the exhaust off for 8+ months, so it was a lil foggy, but common sense goes a long way . If I had used my head and droped the shocks from the getgo, I would have saved myself a LOT of frustration, time, and $30. I didn't mention it, but I also snapped 2 bolts when I first removed the exhaust. I drilled out one straight enough so I could salvage the threads, the other I had to tap to 9/16 :P. Needless to say I'm VERY disappointed in myself, but, no more exhaust leak. I just hope no one goes through what I had to,.. I wouldn't wish it on my worst enemy. Battle isnt over, now it has a lean pop, and it needs a clutch :/. Here I thought I finally won (sigh).