Exhaust header leak,looking for fix tips...

[OldVet66]

I would chase the threads with the same size tap and see if it will hold your bolt before going up a size or using a heli-coil. Heli-coils come with their own installation problems, and you would probably need to use two. Using a larger bolt might require drilling the flange clamp ears a little larger, but all three methods will work. You are just dealing with two bolts I believe, so I would at least try chasing the threads before the other methods.

[Mr.Mom]

Hi,
Got the heli-coils in! Most likely didn't save any money over a shop after all the running around and buying parts/tools I didn't have. Put two in one hole.

Now how the heck do you get out those exhaust gaskets!...?

Thank you

[UncleMike]

Hi,
Got the heli-coils in! Most likely didn't save any money over a shop after all the running around and buying parts/tools I didn't have. Put two in one hole.

Now how the heck do you get out those exhaust gaskets!...?

Thank you

Can't put a price on knowledge and skill.

Love a happy ending.

As for the exhaust gaskets, they just come right out?

[OldVet66]

A small angled pick will remove the gaskets. They unravel when you catch them right. I got a set at Lowes. It also had one that is a 3/4 circle on the end that works like a champ removing the clips on the rear brakes.

[JTGS850GL]

Getting the gaskets out is usually a piece of cake. I just take a small flat screw diver and poke it in the center and push it to the center of the hole. The gasket will just curl in and come right out. Just try to not gauge the head.

[Grimly]

Hi,
Got the heli-coils in! Most likely didn't save any money over a shop after all the running around and buying parts/tools I didn't have. Put two in one hole.

Excellent! And now, the next time you come across similar, you'll breeze right in, with no fear - until it bites you on the ass

[Mr.Mom]

Got the bike put back together. Runs smoother with the new intake o-rings, but
I still get a poppity pop from the exhaust, even with 2 gaskets squeezed down @ 12 ft/lbs. At certain rpms the exhaust gets noticeably louder, as if some of it is coming out the front instead of the muffler. I suspect at certain engine pressures the exhaust is blowing past the new gaskets on one or more pipes.
I am using gaskets from Z1.

Any advice for stubborn exhaust leaks?

Thank you

[OldVet66]

Are you sure you got all of the old gasket material out? The bore recessed in the heads is quite well defined when clean. I just ask because those old smashed gaskets look like part of the head until you get them cleaned out and learn better.

[MK3Brent]

Did you take the new seal and match it up to the header pipes? Curious if they match up in size. My seals were slightly larger on the ID that the ID of my pipes. And it didn't seal properly.

Still waiting for my new Cu seals. Should match up better once crushed.

[Mr.Mom]

Cleaned them out well.


No I didn't check the i.d. Put them in the head and they fit snuggly and looked like they covered the old marks. I suppose I should check the i.d.

Thank you.

[MK3Brent]

Cleaned them out well.


No I didn't check the i.d. Put them in the head and they fit snuggly and looked like they covered the old marks. I suppose I should check the i.d.

Thank you.

Yeah, I did the same thing.
Didn't even think to look, just put them in the head. When it leaked, I pulled them back out and matched them up to the pipes. No good!

[OldVet66]

Sounds to me like the clamp ears are bent or your bolts too long (unless you used studs) to get proper compression on the gaskets.