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Exhaust leak at connection. Slip on to header. (Read 77 times)

Dad0220 Junior Member Offline SuzukiSavage.com Rocks! Posts: 66	Exhaust leak at connection. Slip on to header. 04/10/18 at 07:38:41 The 2006 boulevard S40 that I recently bought has a Jardine slip on muffler clamed to the header pipe. Whoever installed it didn't use the proper clamp or reducer because it leaks at the connection. can anyone tell me what I need to make it right? I would appreciate it. Thanks
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Dad0220 Junior Member Offline SuzukiSavage.com Rocks! Posts: 66	Re: Exhaust leak at connection. Slip on to header. Reply #1 - 04/10/18 at 07:45:38 Here's what I have.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Exhaust leak at connection. Slip on to header. Reply #2 - 04/10/18 at 09:22:37 I had one of those. I made it right by getting an adapter made and putting a Dyna muffler on. If you're just wanting to stop the leaking, I don't know what you need to do exactly, but the T-clamp is set wrong. Loosen, slip just to the end of the slots, covering the slots. Cheap T-clamps aren't your friend.
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Dad0220 Junior Member Offline SuzukiSavage.com Rocks! Posts: 66	Re: Exhaust leak at connection. Slip on to header. Reply #3 - 04/10/18 at 09:28:30 Thanks, I was thinking about going to a local muffler shop and seeing if they could weld it together. I'm not sure if it's something they'd do because they can't raise it on a lift to work on it.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Exhaust leak at connection. Slip on to header. Reply #4 - 04/10/18 at 09:39:01 Yeah, there is a reason mufflers aren't welded on.. If it's backfiring hard, check the header and cylinder connection. Is that muffler connected to the frame?
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Re: Exhaust leak at connection. Slip on to header.
Reply #5 - 04/10/18 at 09:57:06

The clamp they use on HD mufflers is the widest heavy duty clamp I've used. If you cut 6 slots in the mounting end and use the same process as mounting a Dyna ,it should seal . the trick is to cut a section of a "tin" can that has the ripples in it ,ends cut at a 45 degree angle , and place it between the exhaust pipe end and the muffler ,and clamp tightly . the ripples being crushed act as a series of seals . I've used this method many times with Dyna's and have no leaks, and JOG makes a point the muffler does need to be supported ,if it's allowed to flop around your connection will fail at some point.

my old work mates called me MacGyver

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Dad0220 Junior Member Offline SuzukiSavage.com Rocks! Posts: 66	Re: Exhaust leak at connection. Slip on to header. Reply #6 - 04/10/18 at 10:47:03 Backfires occasionally, so I’ll check header pipe to cylinder head bolts. Tge muffler is bolted on using the same bracket and bolts that held the stock muffler on.
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Tocsik Serious Thumper Offline the singularity Posts: 1163 Denver, CO Gender:	Re: Exhaust leak at connection. Slip on to header. Reply #7 - 04/10/18 at 11:10:26 careful checking those header to cylinder bolts/nuts. 1/4 inch ratchet with only finger tips on the handle. Ya don't wanna strip them. the rippled tin can gasket is the ticket here. Check out the thread on mounting a dyna muffler and use the same technique in your Jardine.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Exhaust leak at connection. Slip on to header. Reply #8 - 04/10/18 at 11:20:02 Occasional backfiring is normal. With a Jardine, it's almost impossible to avoid it.
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Dad0220 Junior Member Offline SuzukiSavage.com Rocks! Posts: 66	Re: Exhaust leak at connection. Slip on to header. Reply #9 - 04/10/18 at 13:37:51 Thanks for all of the input. I'll be saving an empty (rippled) can or two after I feed the dogs tonight. I'll probably try it Saturday and I'll post an update.
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