SuzukiSavage.com - 2004 S40 exhaust header to can gasket(s)

mylovelyhorse

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2004 S40 exhaust header to can gasket(s)
01/30/21 at 04:51:37

Hi,

I have removed my header & can for cleaning and polishing. The gasket between can & header was in poor condition so I binned it. Now i need a replacement and I've looked at CMSNL for the part(s). I'd be grateful for advice.

Copper or not copper - or both? Which exhaust gasket would you use?

This copper looking one: https://www.cmsnl.com/suzuki-ls650p-savage-2004-l4-usa-e03_model34982/connect...

OR

this one (which I think is what came off) https://www.cmsnl.com/suzuki-ls650p-savage-2004-l4-usa-e03_model34982/connect... ?

OR do I need both?

I want to do the best for my bike and the tiny price difference is irrelevant. Thoughts & advice would be appreciated.

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mylovelyhorse

2004 S40 Boulevard (grey import to UK)
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Hiko Senior Member Offline SuzukiSavage.com Rocks! Posts: 250 Tauranga New Zealand Gender:	Re: 2004 S40 exhaust header to can gasket(s) Reply #1 - 01/30/21 at 14:56:19 When I fitted my harley muffler someone on here suggested using the corrugated part of a fruit can cut into strips to fit. So I did That was about 10000kms ago Works fine I think the fruit was good too from memory Peaches I think
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4406 Honolulu	Re: 2004 S40 exhaust header to can gasket(s) Reply #2 - 01/31/21 at 11:12:49 Why not use an OEM part? Like from the Suzuki dealer, Partzilla, Babbitts, etc. I don't think you will get a better quality aftermarket part. The genuine Suzuki item is top notch.
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norm92de Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1180 El Paso TX Gender:	Re: 2004 S40 exhaust header to can gasket(s) Reply #3 - 01/31/21 at 17:41:40 DBM, I too am an OEM person. No foreign parts for me.
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Hiko Senior Member Offline SuzukiSavage.com Rocks! Posts: 250 Tauranga New Zealand Gender:	Re: 2004 S40 exhaust header to can gasket(s) Reply #4 - 01/31/21 at 23:51:24 It was a while ago now but I think the reason was the harley muffler inlet was a different size to the old suzuki one so the oem gasket would not fit
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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2778	Re: 2004 S40 exhaust header to can gasket(s) Reply #5 - 02/02/21 at 11:30:01 OEM FTW!
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: 2004 S40 exhaust header to can gasket(s) Reply #6 - 02/02/21 at 16:41:55 Whatever works FTW! If a piece of tin can works Why not?
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Hiko

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Re: 2004 S40 exhaust header to can gasket(s)
Reply #7 - 02/03/21 at 23:18:26

Actually I find some of these comments amusing and confusing all at once

Nothing but Oem for me! is the cry Really???

I love the savage s40 but this is a forum where many non Oem changes are
made and advocated Tyres, the head plug , the cam tensioner , the rear pulley bearings led lights , carb jetting the list goes on and on
and we get all twisted and bent over a non oem exhaust gasket that has been proven to work?

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ohiomoto

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Re: 2004 S40 exhaust header to can gasket(s)
Reply #8 - 02/05/21 at 16:11:13

Hiko wrote on 02/03/21 at 23:18:26:

Actually I find some of these comments amusing and confusing all at once

Nothing but Oem for me! is the cry Really???

I love the savage s40 but this is a forum where many non Oem changes are
made and advocated Tyres, the head plug , the cam tensioner , the rear pulley bearings led lights , carb jetting the list goes on and on
and we get all twisted and bent over a non oem exhaust gasket that has been proven to work?

--------------

Good point but I'm not all twisted or bent over about it. I would use your method if I needed to. (Thanks for sharing it!) But, the OEM unit isn't something that needs improvement. They are reliable and easy enough to get. I would rather just save my time and buy one. That's just me.

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Yoshi Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 874 LongIsland, N.Y. Gender:	Re: 2004 S40 exhaust header to can gasket(s) Reply #9 - 02/10/21 at 20:06:52 I have found that cutting a few extra slits in the dyna muffler allows a clamp to actually clamp the muffler better to the header, No need for a gasket.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18115 Camp Springs, Kentucky Gender:	Re: 2004 S40 exhaust header to can gasket(s) Reply #10 - 02/11/21 at 02:44:39 The original question by member "mylovelyhorse" is about the stock header and stock muffler.
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mylovelyhorse

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Re: 2004 S40 exhaust header to can gasket(s)
Reply #11 - 02/14/21 at 14:53:37

DragBikeMike wrote on 01/31/21 at 11:12:49:

Why not use an OEM part? Like from the Suzuki dealer

Good question. Partly because the local Suzuki dealers here in the UK don’t hold stock parts for 2004 bikes and while they will order them in for me and add on a surcharge for doing so, I don’t want to wait ages.

Quote:

Partzilla, Babbitts, etc.

Who? Are they perhaps American parts resellers?

Quote:

The genuine Suzuki item is top notch.

I take it you didn’t notice that both the links I posted were for genuine OEM parts?

The question was really meant to read “do I need one, the other or both”. Do you know if I need one, the other or both gaskets? I don’t know, you see, and the Clymers manual, along with the micro-fiches online at Fowler’s Parts & CMSNL aren’t clear.

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mylovelyhorse

2004 S40 Boulevard (grey import to UK)
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mylovelyhorse

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Re: 2004 S40 exhaust header to can gasket(s)
Reply #12 - 02/14/21 at 14:56:19

Dave wrote on 02/11/21 at 02:44:39:

The original question by member "mylovelyhorse" is about the stock header and stock muffler.

Thank you, yes it was. I’ve ordered both parts and will see what I can do when they turn up to get the exhaust back on the bike. In the meantime I have plenty of other things to be getting along with as I put the bike back together

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mylovelyhorse

2004 S40 Boulevard (grey import to UK)
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DragBikeMike

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Re: 2004 S40 exhaust header to can gasket(s)
Reply #13 - 02/15/21 at 01:53:31

Part number 14771-24B01 fits 1986 thru 2004 LS650.

Part number 14771-46E00 fits 2005 on.

Sorry, I didn't notice those OEM part numbers on the links you provided. I have no idea if the "connector" for the late model LS650 will fit your 2004. There is only one gasket "connector" in the assembly, its does not use two pieces. Since you ordered both, you should have no trouble getting it assembled, one or the other part should work.

Also, sorry that I didn't note that you are in the UK. I don't know if Babbitts or Partzilla ship overseas. They are US parts outlets that sell OEM parts. Here are some links that might be helpful.

https://www.partzilla.com/catalog/suzuki/motorcycle

https://www.suzukipartshouse.com/oemparts/c/suzuki_motorcycle/parts

Best regards, Mike

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mylovelyhorse

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Re: 2004 S40 exhaust header to can gasket(s)
Reply #14 - 02/15/21 at 05:30:39

Thanks a lot for the reply, Mike, I appreciate it.

Looks like I'll have one spare gasket then - although I can always eBay that and hope to recoup some of the £££.

I'm afraid that while the cost of postage from the EU has tripled since we (stupidly) left the EU, it's still cheaper than buying from the US. I often see things advertised at, eg $10 - plus $25 postage. It very rapidly increases as weight and/or size goes up :'(

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mylovelyhorse

2004 S40 Boulevard (grey import to UK)
5,500 miles
Mods: Raptor fuel tap

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