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[easttnrhino]

Installed my fullsac head pipe and matertune the other day and when I first start it  sounds like a exhaust leak around back cylinder, when the bike warms up it goes away, sad part is I can not tell you if it did it before the install, any body got any ideas.  Thanks

[cembo]

Installed my fullsac head pipe and matertune the other day and when I first start it  sounds like a exhaust leak around back cylinder, when the bike warms up it goes away, sad part is I can not tell you if it did it before the install, any body got any ideas.  Thanks

Blow some smoke toward the flanges with the engine idling. might be that the gasket is not sealing properly. Did you exchange the gaskets when you swapped the headers??

[North Georgia Hawg]

Here's my idea... Always use NEW crushable exhaust gaskets when mounting headers... whether mounting now or remounting. If you have a leak, the best thing to do is to remount the pipe with new crushable gaskets. They are cheap... only a few dollars.

It's far easier to remount the headers with new gaskets than it is to try to figure out if there's an exhaust leak... and if there is, the cure is to remount with new gaskets anyway.

Ken

[Fullsac Performance]

Did I call that one or what! Lol..

SG

[easttnrhino]

Wow explain please Steve

[Fullsac Performance]

Wow explain please Steve

PM sent.

[jachd17]

PM sent.

 Curiosity factor growing by those who have seen this thread

[hdaliaconis]

  ??

PM sent.

[HOGMIKE]

Here's my idea... Always use NEW crushable exhaust gaskets when mounting headers... whether mounting now or remounting. If you have a leak, the best thing to do is to remount the pipe with new crushable gaskets. They are cheap... only a few dollars.

It's far easier to remount the headers with new gaskets than it is to try to figure out if there's an exhaust leak... and if there is, the cure is to remount with new gaskets anyway.

Ken

 
That's why Fullsac ships new gaskets with their headers...........at least IIRC?
 

[Fullsac Performance]

OK I will explain, but please don't kick me in the balls too hard if you disagree.

When I change headpipes on my own bikes, I never replace the factory exhaust gaskets. The OEM gaskets are installed with a special tool and are very high quality. I have changed headers over twenty times on the same set of OEM exhaust gaskets and never had a leak. Rhino called me the other day with his concerns. I asked him if he changed the gaskets and he said no. I said good because many times guys will attempt to install the new gasket we provide with out an installation tool and damage them resulting in an exhaust leak. If I speak to an individual who is installing my header and removing his for the first time I will tell them its OK not to change the original gaskets, I do it all the time with out issue. If you are going to change them great, but it must be done correctly or you may create a problem that wouldn't have existed had you left the originals in place.

I also told him not to mention this on the forum because people would insist they must be changed!
Called that one! Lol.. Sorry for the suspense.

Got my fire suit on, Flame away!

SG

[T-Roy]

OK I will explain, but please don't kick me in the balls too hard if you disagree.

When I change headpipes on my own bikes, I never replace the factory exhaust gaskets. The OEM gaskets are installed with a special tool and are very high quality. I have changed headers over twenty times on the same set of OEM exhaust gaskets and never had a leak. Rhino called me the other day with his concerns. I asked him if he changed the gaskets and he said no. I said good because many times guys will attempt to install the new gasket we provide with out an installation tool and damage them resulting in an exhaust leak. If I speak to an individual who is installing my header and removing his for the first time I will tell them its OK not to change the original gaskets, I do it all the time with out issue. If you are going to change them great, but it must be done correctly or you may create a problem that wouldn't have existed had you left the originals in place.

I also told him not to mention this on the forum because people would insist they must be changed!
Called that one! Lol.. Sorry for the suspense.

Got my fire suit on, Flame away!

SG

When I changed my exhaust I was luck to have two buddies of mine give that hint because they had already been down that road themselves. I kept my original gaskets in place. Thank God for good buddies!!

[Cat Eye]

Just installed two DX Pipe and did change the exhaust gaskets...(would have been nice if Steve would have shared his experiences a couple day earlier)  any hoot...they are tricky to install.  I have learned that a good coating of assembly lube makes the gasket slide in much easier. 

[Phantom309]

Installed my fullsac head pipe and matertune the other day and when I first start it  sounds like a exhaust leak around back cylinder, when the bike warms up it goes away, sad part is I can not tell you if it did it before the install, any body got any ideas.  Thanks

I've changed exhaust on quite a few of my bikes and never had any leaks, I hate exhaust leaks with a passion. I always opted for new OEM gaskets, just figured you're there, they're cheap enough so why not. You could get away with the originals provided you didn't gouge them up too bad when removing the pipes ... if they look cherry then re-use them, but not me. Do you really want to rip it all back apart and do the job a 2nd time cause you were lazy or cheap or both? ... not me!

New gaskets are a little tricky to install correctly, but some patience goes a long way. I always worked them in evenly as far as I could with my fingers then some easy taps with a socket that matches it, but don't force them.  If you don't have them fully seated and they are even and close, the pipes will draw them in the rest of the way when you tighten the flanges.

Here's a trick I have always used on all my cars, trucks and bikes that I put exhaust on that just might fix that little tick you have on the rear cyl. After wiping all your chrome off, checking for any possible leaks and going off on it's maiden voyage ... ride it all day getting everything nice and hot. When you park it for the night and get up the next day, re-torque everything again while the bike is ice cold in the exact fashion the service book tells you and it should be fine unless you butchered that gasket. I tend to stay in the middle to upper end of the torque specs for initial install and 1st ride then max them out on the 2nd one ... I do start off at the specs I left off at for the re-torque first then I go to max just to see how much everything really did loosen/settle in. After one good hot/cold cycle like that everything usually takes a little tweak and should seal up and be good for a long time ... always worked for me cause I'm real fussy if you couldn't tell. Good luck and let us know.     

 

[hdaliaconis]

Totally agree!

OK I will explain, but please don't kick me in the balls too hard if you disagree.

When I change headpipes on my own bikes, I never replace the factory exhaust gaskets. The OEM gaskets are installed with a special tool and are very high quality. I have changed headers over twenty times on the same set of OEM exhaust gaskets and never had a leak. Rhino called me the other day with his concerns. I asked him if he changed the gaskets and he said no. I said good because many times guys will attempt to install the new gasket we provide with out an installation tool and damage them resulting in an exhaust leak. If I speak to an individual who is installing my header and removing his for the first time I will tell them its OK not to change the original gaskets, I do it all the time with out issue. If you are going to change them great, but it must be done correctly or you may create a problem that wouldn't have existed had you left the originals in place.

I also told him not to mention this on the forum because people would insist they must be changed!
Called that one! Lol.. Sorry for the suspense.

Got my fire suit on, Flame away!

SG

[North Georgia Hawg]

OK I will explain, but please don't kick me in the balls too hard if you disagree.

When I change headpipes on my own bikes, I never replace the factory exhaust gaskets. The OEM gaskets are installed with a special tool and are very high quality. I have changed headers over twenty times on the same set of OEM exhaust gaskets and never had a leak. Rhino called me the other day with his concerns. I asked him if he changed the gaskets and he said no. I said good because many times guys will attempt to install the new gasket we provide with out an installation tool and damage them resulting in an exhaust leak. If I speak to an individual who is installing my header and removing his for the first time I will tell them its OK not to change the original gaskets, I do it all the time with out issue. If you are going to change them great, but it must be done correctly or you may create a problem that wouldn't have existed had you left the originals in place.

I also told him not to mention this on the forum because people would insist they must be changed!
Called that one! Lol.. Sorry for the suspense.

Got my fire suit on, Flame away!

SG

Interesting info, Steve. Absolutely no flaming from me! You are the expert, and you've changed orders of magnitude more exhausts than I ever will.

I just always used new gaskets because I don't want them to be a problem later...  especially with different pipes that may have different curves at the attachment point. I twist the old ones out with needle nose pliers, and gently push the new ones in all around until they seat. It takes all of 5-10 minutes to get the old ones out, clean up the seats, and put the new ones in, I've never had an issue with doing this. Now, if I were doing several bikes a DAY, I might think differently! 

Re-torquing after the bike has been ridden and the pipes are cold again, as easttnrhino said, is a very good idea too.

Ken