Exhaust Install

[zed7fiddy]

Ok so I would have thought the installation of my new sports exhaust would be straightforward... and it basically is. I do have a couple of questions though as something to me doesn't seem quite right.

Forgive me for not knowing the "technical" names of all these parts - I hope you can discern what I'm talking about.

The problem is not the top mounting so much (the one that holds the exhaust in place) but the bottom one. The standard exhaust has a graphite? insert which fits inbetween the outer edge of the front pipe and the inner edge of the pipe which feeds into the exhaust. My new exhaust however, has a different diameter and the insert does not fit inside or outside it. (See photos)

As such, when I put it on and bolt the bottom pipes together with the clamp, I can feel exhaust gases leaking out of the bottom connection. Something tells me it's not supposed to be like that

The guy I bought the exhaust from says everything I need to install it comes in the kit but there isn't one of those inserts. So I'm a little confused.

Help appreciated.

The first photos are of the standard exhaust, in the other photo the standard exhaust is on the left, and the new one on the right.

[beau042]

if its a slip on system they normally have a small hole on the join for gases to come out, thou if its coming from around the join itself sounds like you need the exhaust gasket, what brand of pipe is it?

[zed7fiddy]

if its a slip on system they normally have a small hole on the join for gases to come out, thou if its coming from around the join itself sounds like you need the exhaust gasket, what brand of pipe is it?

It's an IXIL exhaust. It didn't come with the gasket though, so I'm confused...

[ApatheticEnd]

You should be able to splay the link pipe out a bit to fit it together, then clamp it down. Leave the gasket on the outside of the smaller diameter part of the link rather than in inside of the other.

[ufatbarstard]

Exhaust Assembly Paste

• Soft paste for fast, easy and absolute gas tight
sealing of flanges and slip fittings in the exhaust
system.
• No welding necessary.
• Due to the exhaust heat the paste becomes metal
hard.
• Temperature resistant up to approx. 700C.
• Tightens up permanently.
• Shock and vibration resistant.

Available from Coventrys - try Wangara

[zed7fiddy]

You should be able to splay the link pipe out a bit to fit it together, then clamp it down. Leave the gasket on the outside of the smaller diameter part of the link rather than in inside of the other.

The new pipe is a pretty snug fit, and the gasket from the standard pipe is much too thick to use even if I was able to try and squeeze it around the outside of the pipe.

The standard exhaust pipe fits around the outside of the front pipe connection (including the gasket) whilst the new exhaust fits INSIDE the front pipe connection rather snugly, but still "leaks" when clamped.

Hopefully that explains it a little better.

Exhaust Assembly Paste

I'll look into that, cheers

[rc_sam]

+1 on using the paste.

[jules_1972]

Paste is great, sucks getting it apart though...

[zed7fiddy]

Yes that's exactly why I am a bit hesitant on pasting it together. I don't think I'd get a gasket in there even if there was one the right diameter - the fit is too snug. Am I just not clamping it tight enough?

[Arwon]

just put it on, it is the final connection and most exhausts are just a slip fit with no joining paste.
After a short time it will clog up any small gap with carbon anyway.

[zed7fiddy]

just put it on, it is the final connection and most exhausts are just a slip fit with no joining paste.
After a short time it will clog up any small gap with carbon anyway.

Ahh alright, that makes sense to me. Thanks for the input I'll try it again and see how I go (it sounds AWESOME by the way I'm so excited )

[not faz]

I put a two brothers on my R1 and had a similar issue. But the kit came with a tube of the high temp silicone gasket. You will be able to buy it from repco or supercheap. Some remain slightly flexible so disassembly isn't a problem.
Good luck either way.

[zed7fiddy]

hmm I may try that. I took it for a spin today and the leak is minimal, it may just expand under the heat and be fine for a longer ride. I'll have a word to my mechanic about it and getting some filler stuff and we'll see how we go.

[zed7fiddy]

All finished, thanks for all the info peeps, appreciate all the help/advice that was given.

I spoke to my bike mech who said a combination of everything that was said here, that if the leaks are really minor it wouldn't matter too much as long as there is no "flat spots" in the acceleration (indicating the engine is probably running too lean). As for the tuning, PCIII and other stuff, he said it's probably not necessary for just the exhaust, it all depends what you want to spend really. Just gotta check the plugs at the next service to make sure they're not white and if not it's all sweet the way she is.

He gave me some maniseal exhaust cement to dab around the joints to seal up the little leaks and it's all sweet.

Pics as follows, me iz happy!