Topic: Exhaust leak

[evinrude7]

Fairly certain I have an exhaust leak where the 3 or 4 header connects to the head.  I only notice it when the bike is cold but could always be there. Last time I reinstalled the exhaust I took out the old crush washers, put in new and cranked down on the screws holding the exhaust flanges. Ran through a few heat cycles and did it again. Any ideas? Could I possibly take a dead blow to the flanges and try tightening the flange screws again?

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[ekpent]

 Just so people know your running original exhaust and normally we refer to the flanges as spigots.  Sometimes if you have an exhaust leak there there might be some tell tale residue around the spigot area. What you want to do probably won't hurt anything but if you had to drop the exhaust to do it you might as well pop in a new crush gasket while its apart.

[bustech51]

Check to see if the seating area of the crush gasket is not built up with some carbon deposits.  That is what happened to me.  I took a small straight wire wheel on my drill and cleaned it up on the head side as well as the pipe side.  Problem solved on mine.

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[PeWe]

Or if there is an old copper gasket sitting there under your newer. They can sit hard and look sooty.

[newday777]

Or if there is an old copper gasket sitting there under your newer. They can sit hard and look sooty.

Exactly what I was thinking before getting to your reply Per. Many have looked and thought there wasn't an old gasket in there and missed taking out the old crushed gasket.

[Little_Phil]

I presume you notice it by the (distinctive) sound. If you disconnect the coil feed to a cylinder and run the bike briefly on three and that noise stops, that's your cylinder.