SuzukiSavage.com - Re: Bad Header?

Serowbot

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Re: Bad Header?
04/19/12 at 16:40:04

Naa,.. crappy welds are par for the course in a Savage...
Never seen a header flange warped like that before... but, you have a new one, right?...
???.. How do you install a new flange?... does it slide over that doodaa at the bottom of the pipe?... Just wonderin'...

Anyway,.. when mine leaked,.. I installed a new gasket over the old one (double)... that worked for me...

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Fish

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Re: Bad Header?
Reply #1 - 04/19/12 at 16:54:17

Hey Moderators, can one of you delete this thread please? I messed it up.

EDIT: Looking at some things again and looking at the motorcycle handyman CD I now realize that that area inside the exhaust header can in no shape or manner be my problem. SORRY GUYS. I'm still a newb and this is my first bike that I haven't done much tinkering on. I thought from one picture I had seen that the gasket was supposed to fit inside

Thanks for the replies

I have had this Dyna stamped with part # 64941-01 sitting around forever now. I figured that since I have my exhaust apart I might try putting it on. Isn't it supposed to butt all the way up to that ring on on the header?

It doesn't seem to want to fit:

I've read about several people installing Dynas, I've never seen anyone have this problem.
What gives?

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« Last Edit: 04/21/12 at 12:09:54 by Fish »

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28635 Tucson Az Gender:	Re: Bad Header? Reply #2 - 04/19/12 at 16:57:42 I'd get new factory bolts too, when you pick up a fresh gasket... worth a try... (besides... they're pretty)... Best luck... ...
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Fish

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Re: Bad Header?
Reply #3 - 04/19/12 at 17:09:58

Yeah, the new bolts, flange, and gasket were all OEM parts.

Here's a picture I snapped when they arrived at my doorstep via UPS THROWING the box against my front door:

The gasket was from a local dealership and the bolts and flange came from Bike Bandit.

Well now that there's no gasket in there the flange fits flush.

Slow moment: Because it's a "Crush" gasket is the flange not supposed to fit flush with the head until a new gasket is fully crushed in by fully seating the bolts in the header flange?

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28635 Tucson Az Gender:	Re: Bad Header? Reply #4 - 04/19/12 at 18:38:48 If you "crush the gasket that far (flush),... you over-tightened... ... and you will break your new flange.. Spec is 12lbs I think...anyway,... feel it bite, firm... but don't break it. It don't go home,.. just to tight...
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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Bad Header? Reply #5 - 04/19/12 at 19:20:23 ITEM N-m \| ft-lb Exhaust pipe clamp bolts 18.0 28.0 \| 13.3 20.6
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28635 Tucson Az Gender:	Re: Bad Header? Reply #6 - 04/19/12 at 19:24:55 Serowbot wrote on 04/19/12 at 18:38:48: Spec is 12lbs I think...anyway,... BZZT!!!.. I was wrong... ... ...(so,.. is that 13,.. or 20...?)... (or is the left one different than the right one?)... The mind,.. wobbles... ...
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Bad Header? Reply #7 - 04/19/12 at 21:01:31 No flange,, slide it down,,out of the way, run a bolt in & see how it feels. Use a small wire & see how deep the hole is,.Compare to how far bolt screws in,, If its really not goin in all the way,, say something, Ill explain the next step,
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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Bad Header? Reply #8 - 04/19/12 at 21:13:23 I've had the same problem, just put it in a vice and straighten it out.
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Fish Full Member Offline Who Shot Who In The What Now? Posts: 213 (near) Tampa, FL Gender:	Re: Bad Header? Reply #9 - 04/21/12 at 10:30:26 The bolts do thread all the way down in without the flange and header there. Should I grind down that bit of extra crap from the weld in the header with a dremel if I can get my hands on one? I picked up a new header gasket last night seeing as how the last one in there disintegrated.
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28635 Tucson Az Gender:	Re: Bad Header? Reply #10 - 04/21/12 at 10:42:35 That weld ain't hurtin' nuttin'...
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Fish Full Member Offline Who Shot Who In The What Now? Posts: 213 (near) Tampa, FL Gender:	Re: Bad Header? Reply #11 - 04/21/12 at 10:46:45 verslagen1 wrote on 04/19/12 at 21:13:23: I've had the same problem, just put it in a vice and straighten it out. The flange? Or the header pipe? I replaced that warped flange with a new, flat one a couple of weeks ago.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Bad Header? Reply #12 - 04/21/12 at 11:12:14 If your exhaust ever worked right, then that weld isnt a problem,, unless you think its grown lately,
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Fish Full Member Offline Who Shot Who In The What Now? Posts: 213 (near) Tampa, FL Gender:	Re: Bad Header? Reply #13 - 04/21/12 at 11:16:56 UPDATE I finally realized something I was totally overlooking with the header issue. Thanks for the responses. How about a hand with that muffler fit?
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justin_o_guy2

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What happened?

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East Texas, 1/2 dallas/la.

Re: Bad Header? Update: Dyna Muffler Issue
Reply #14 - 04/21/12 at 11:30:03

I'd just gently play with it & try to get it together & get stuff to go in straight & all,, if it just wont, then Id put a dab of silicone or oil or something where I thot the obstruction is & try again,, if the goo transfers, then its hitting,,

Time consuming,, yea, may hafta play a while to find it,,
You can also get a can of dye from a machine shop supply, IDK what it costs. Its a rattle can sized can.

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