SuzukiSavage.com - Exhaust Leak: tighten bolts or replace gasket

BGregg

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Exhaust Leak: tighten bolts or replace gasket
11/19/18 at 07:08:14

I've read on the forum that if you have an exhaust leak at the head you should replace the gasket. I also read that you should regularly check the tightening on your header bolts as they loosen over time.

My question is this: is it to late to tighten the bolts once it starts leaking? Is the tightening the preventative maintenance of the leak but once it's started the gasket damage is already done?

Thanks

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BGregg YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Exhaust Leak: tighten bolts or replace gasket Reply #1 - 11/19/18 at 07:14:57 I already ordered the new gasket and will be replacing it. I'm just asking for future reference.
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Re: Exhaust Leak: tighten bolts or replace gasket
Reply #2 - 11/19/18 at 08:08:55

The exhaust bolts at the cylinder can be an issue - especially if the bike is stored outside and subject to damp conditions.

There are 2 distinct problems with the bolt. They either loosen - or they become corroded and get stuck in the head and break off (big problem).

Remove the bolts 1 at a time and clean them, and apply anti-sieze and snug them up with one hand on a very small wrench (1/4" drive ratchet or small wrench). Don't over tighten them and break them off or strip the threads. Check the tightness now and then......some of them never loosen and some do - you will learn after a few checks if you need to worry about them.

If your exhaust continues to leak after cleaning and tightening....then your gasket is likely ruined. The flange should not be touching the head, if the gasket is of proper thickness and not worn - the bolts will snug up before the flange touches the head.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Exhaust Leak: tighten bolts or replace gasket Reply #3 - 11/19/18 at 08:12:37 Depends.. You can usually snug them up and it's okay. If it leaks long enough to cut the seal, Ooopsies. Be cool with those tiny little bolts. You're much better off having to snug them occasionally than trying to get a broken one out.
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BGregg YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Exhaust Leak: tighten bolts or replace gasket Reply #4 - 11/19/18 at 08:19:23 Will do, thanks for the information. I'll see if applying anti sieze and re tightening works. Luckily I have the gasket on order just in case.
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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2772	Re: Exhaust Leak: tighten bolts or replace gasket Reply #5 - 11/19/18 at 12:32:43 It could also be that the header pipe isn't sitting square against the gasket. I would slightly loosen the rest of the system, tighten the header while making sure it seats properly, and then go back and tighten up the rest of the system.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Exhaust Leak: tighten bolts or replace gasket Reply #6 - 11/19/18 at 13:04:10 Being old, I'd try snugging bolts first. If that doesn't work, I'd do what he said. I've had that leak. Snugging always got it. I've removed the exhaust and reused it. Once, I replaced it. I just didn't wanna chance it.
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Re: Exhaust Leak: tighten bolts or replace gasket
Reply #7 - 11/19/18 at 16:21:13

I've removed the gasket and it being flexible , have just squeezed it ,from the inside and outside with my thumb and fingers which helps to restore a bit of it's thickness ,before retightening. I have never replaced it even though my exhaust has been off many times on my 95 (owned since new). snug is good ,over tightening flattens it and may lead to early replacement/ and bolts seizing .

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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2772	Re: Exhaust Leak: tighten bolts or replace gasket Reply #8 - 11/20/18 at 12:47:42 justin_o_guy2 wrote on 11/19/18 at 13:04:10: Being old, I'd try snugging bolts first. If that doesn't work, I'd do what he said. ------------- Yes, that first of course.
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BGregg YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Exhaust Leak: tighten bolts or replace gasket Reply #9 - 11/26/18 at 06:15:07 I just got the gasket and anti sieze in so I'm about to try tightening the bolts prior to a possible gasket replacement. Is this a normal amount of compression on the gasket?
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Exhaust Leak: tighten bolts or replace gasket Reply #10 - 11/26/18 at 06:39:48 Looks OK to me.....if the flange touches the head - it is definitely time for a new gasket.
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BGregg YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21	Re: Exhaust Leak: tighten bolts or replace gasket Reply #11 - 11/26/18 at 06:43:54 Bolts were real easy to tighten. I snugged them up. Gonna take it for a test ride to see if it fixed the leak. Idling in the parking lot it seemed like it was fixed.
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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2633 Amongst the Twisty Roads	Re: Exhaust Leak: tighten bolts or replace gasket Reply #12 - 11/26/18 at 10:56:27 The bolts get tightened to 13-20 ft/lbs - it's not how it looks.
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Tocsik Serious Thumper Offline the singularity Posts: 1163 Denver, CO Gender:	Re: Exhaust Leak: tighten bolts or replace gasket Reply #13 - 11/27/18 at 06:35:21 I've read on here that you can stack those exhaust gaskets if/when they flatten. Seems to me like it could be a source of leak but it was described by someone in this group.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Exhaust Leak: tighten bolts or replace gasket Reply #14 - 11/27/18 at 07:13:45 One gasket works fine. If it's time to replace it, just replace it.
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