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Exhaust seal knackered
44 posts · Started by Colonel_Klinck · 07 Jul 2010
Post 2 by scamb66,
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Post 3 by Ya Mother,
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Post 4 by scamb66,
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Post 5 by Ya Mother,
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Post 6 by No. 47,
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Post 7 by emuexport,
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Post 8 by Ya Mother,
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Post 9 by No. 47,
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Post 10 by BASH69,
#10As simple as this really:
All to OE part dimensions plus chamfer to all edges and slot in lieu of material 'malleability' of OE part - was looking at using copper/copper alloy but was machined from solid alloy billet at suggestion of supplier - as such, it's a one off prototype only perhaps but if it works, could be machined from standard tube sections.
Will be fitted with exhaust sealant paste or similar.
All to OE part dimensions plus chamfer to all edges and slot in lieu of material 'malleability' of OE part - was looking at using copper/copper alloy but was machined from solid alloy billet at suggestion of supplier - as such, it's a one off prototype only perhaps but if it works, could be machined from standard tube sections.
Will be fitted with exhaust sealant paste or similar.
Post 11 by Colonel_Klinck,
#11Very pretty, seems a shame to stik it in the exhuast
Post 12 by No. 47,
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Post 13 by Ya Mother,
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Post 14 by Stratkat,
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Post 15 by No. 47,
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Post 16 by Plipton,
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Post 17 by No. 47,
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Post 18 by No. 47,
#18the bike is not popping n banging at all - and i cant feel and gases escaping - it just appears to be moving around under pressure - sounds a bitch to change and if its doing no real harm then I will leave it till the second service and let someone else have the grief !
thanks for all the feedback
thanks for all the feedback
Post 19 by loony888,
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Post 20 by gkjnr,
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Post 21 by Stratkat,
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Post 22 by gkjnr,
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Post 23 by Plipton,
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Post 24 by Stratkat,
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Post 25 by Plipton,
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Post 26 by gkjnr,
#26this is the clamp i was talking about,its got a small hook on it that fits into the pipework but gases are leaking from it ,is this normal?
Post 27 by Superdan,
#27Yeah thats where the graphite gasket fits which has been made in aliminium in the previous page.
You need to replace yours see this thread:
http://www.superduke.net/forum/viewtopi ... t=graphite
Has part number on the box.
You need to replace yours see this thread:
http://www.superduke.net/forum/viewtopi ... t=graphite
Has part number on the box.
Post 28 by gkjnr,
#28cheers i,ll order one up , it looks like it might be a bitch to change though
Post 29 by Superdan,
#29It can be, sometimes its just easier to remove the akras or OEM exhaust and Y piece, take off the exhaust hanger by the clutch cover. Undo the front exhaust header bolts, take off the rear ones and then remove the 10" section and replace the gasket, bit of WD40 and slides straight on. Then re assemble.
Depending on your milage I would replace the 2 graphite gaskets that fit between the header and engine too. They do not cost much, look in your parts manual in the KTM manual for part numbers.
Depending on your milage I would replace the 2 graphite gaskets that fit between the header and engine too. They do not cost much, look in your parts manual in the KTM manual for part numbers.
Post 30 by gkjnr,
#30its only done 5k , i might even just leave it til the winter to do it , i don,t imagine a slight leak will cause any harm apart from the noise of the gases escaping its not bothering me
Post 31 by emuexport,
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Post 32 by Plipton,
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Post 33 by No. 47,
#33That joint has been loose on mine for a few thousand miles. Can't just tighten tha clamp so I just ordered one to replace @ my next oil change.
Post 34 by emuexport,
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Post 35 by No. 47,
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Post 36 by MRK-01,
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Post 37 by AGRO!,
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Post 38 by No. 47,
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Post 39 by KTM666,
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Post 40 by harvester,
#40I dont know if this would work but maybe if you put a heap of heat proof silicon on the gasket it might just help it to stay together.
Heat proof silicon has very fine copper or brass filings in it I just dont remember which and can withstand very high temps.
This is what im going to do when mine craps out.
Heat proof silicon has very fine copper or brass filings in it I just dont remember which and can withstand very high temps.
This is what im going to do when mine craps out.
Post 41 by fuel,
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Post 42 by Colonel_Klinck,
#42In that heat and with the vibrations that will go through the header, I'd say there is a real risk of the 2 welding together. It's not that bad a job to put a new one in and after a while I could do it in 20 mins. You should get between 6 and 9k miles to one so it's not like its a common job. Personally I'd stick with the graphite version. Although since fitting my titanium headers it's not an issue as there are no gaskets
Post 43 by scamb66,
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Post 44 by No. 47,
#44Had similar, and other, concerns before I fitted the 'prototype' - all I can say that after 12-15k miles of all year use, there were no signs of corrosion or 'fusion' - the aluminium gasket appeared to start leaking once it had become brittler and thinner, presumably due to heat, vibration, etc and was a little difficult to get out, particularly compared to the OE item which self-destructs.
For me, the main benefit is the 4-5 times longer life of the alternative.
For me, the main benefit is the 4-5 times longer life of the alternative.
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