MAC 4-into-1 exhaust - '81 GS650 - small leak

[BP_redbear]

I recently installed a new MAC 4-into-1 system and there is a bit of leakage where the muffler tube slides over the manifold pipe.

A mechanic at the shop where I purchased the exhaust (I installed it myself) told me to ride it, get it good 'n warm...then tighten the clamp very much. I tried it, and still a bit of blowby.

The sound is not noticeable, but the chrome is slightly black, as you can imagine.

SO, how do seal up the leak? Or, is this just how it is gonna stay?

BP

[waterman]

I might try some new exhaust gaskets. Remove header, dig out old gaskets, replace with new gaskets, reinstall header. Be careful tightening bolts, heads are made of soft aluminum, will strip easily. Also watch on tightening, my exhaust has broken flanges where previous owner got overzealous with wrench. Check to make sure exhaust fits correctly, sometimes the pipes may need a little fine tuning for best fit.

[BP_redbear]

No...the header gaskets are tight. I installed new ones. (After pulling out the old ones).

The leak is where the muffler pipe connects to the main pipe (beneath the footpeg).

[tkent02]

I guess Mac pipes still have quality control issues...
Weld it?

[BP_redbear]

Well, that would certainly stop the leak, except it would leave that part of the pipe without chrome.

The mechanic at the shop told me if it still leaked, to tell the parts manager, and she would probably order a new muffler pipe for me, because he said "That's not right, it shouldn't leak.".

I doubt that a new pipe would change anything. The fit is a pretty snug slip fit, and the pipes overlap a couple of inches.

Maybe this is as goodas it gets.

I will contact the shop, and call MAC.

My first impression of the system when I removed it from the box wasn't great. The steel seemed fairly thin, the manifold flanges considerably less substantial than the originals, and the cheap-looking clamp with the bolt, which is where the leak is. I wondered how well it was going to seal, and now I know. :-(

I expected more for $300.