Need help with exhaust

[Ian400ex]

I put this off till now, I noticed this when I installed the exhaust but it's nothing big and now that I have the free time I'm going to look for a solution.

http://img266.imageshack.us/img266/6427/issue1.jpg (http://img266.imageshack.us/i/issue1.jpg/)

The blue illustrates air, now this air isn't pouring out but it's definitely coming out and I'm sure in 5th half throttle it's making a bit of flow.

The red illustrates the wear mark on the aluminum piece that fits exhaust on the header, I think that is caused from this.

http://img69.imageshack.us/img69/6811/issue2.jpg (http://img69.imageshack.us/i/issue2.jpg/)

The bolt they gave me to use in conjunction with the spacer is a bit longer than that red line. The piece it gets bolted into has two sets of threads and the bolt only goes through one set allowing minor movement.

Also when this bolt gets tightened it usually stops most of the pipe movement but never seems to keep it from moving in 2 days.

http://img508.imageshack.us/img508/6649/1001328.jpg (http://img508.imageshack.us/i/1001328.jpg/)

Hope you guys can help me. ;)

[CJM]

I have the same exhaust and same issues.

I wound up beating the lower mount so it would line up better and push the exhaust closer to the header. I moved the upper mount as well. Its rock solid now.

I then made sure it was as close as possible to the stock header and use the rtv like they say around all the fittings. Then I got a 2 and 1/4 inch exhaust clamp from the shop and tightened it up as much as possible

It still leaks, but its nowhere near as bad. Mine pops when you let off the throttle or downshift from higher gears/speed.

I finally resolved that thats what you get for less than 200 bucks worth of exhaust.

[Ian400ex]

Originally posted by CJM
I have the same exhaust and same issues.

I wound up beating the lower mount so it would line up better and push the exhaust closer to the header. I moved the upper mount as well. Its rock solid now.

I then made sure it was as close as possible to the stock header and use the rtv like they say around all the fittings. Then I got a 2 and 1/4 inch exhaust clamp from the shop and tightened it up as much as possible

It still leaks, but its nowhere near as bad. Mine pops when you let off the throttle or downshift from higher gears/speed.

I finally resolved that thats what you get for less than 200 bucks worth of exhaust.

Yea but it doesn't sound bad. I think they just use the same exhaust but weld different mounts and use different aluminum pieces. This would make it easier for them to produce because none of them are too specialized for one bike.

Anyways, got any pictures? I would appreciate them.

[CJM]

I dont have any pics cause my cam is busted.

Like I said, I loosened everything up really good and smashed that lower mount flange till it moved the muffler as close as possible to the header, RTV'd it like the directions say and used the car exhaust clamp at the end to hold it together.

my other idea was to simply take the header off and go to my buddys muffler shop and have him expand it all the way back 2-3 inches so you dont need the spacer.

[Ian400ex]

Originally posted by CJM
I dont have any pics cause my cam is busted.

Like I said, I loosened everything up really good and smashed that lower mount flange till it moved the muffler as close as possible to the header, RTV'd it like the directions say and used the car exhaust clamp at the end to hold it together.

my other idea was to simply take the header off and go to my buddys muffler shop and have him expand it all the way back 2-3 inches so you dont need the spacer.

Lol I don't wanna smash it though, I'll see what I can do. Thanks!

[CJM]

Originally posted by Ian400ex
Lol I don't wanna smash it though, I'll see what I can do. Thanks!

I just moved it a bit, I tried everything possible to make it get closer and no matter what I did that lower flange is what the problem is.

Just get a small 3-4lb sledge and give it a few good whacks forward.

[Ian400ex]

Originally posted by CJM
I just moved it a bit, I tried everything possible to make it get closer and no matter what I did that lower flange is what the problem is.

Just get a small 3-4lb sledge and give it a few good whacks forward.
Alright, thank you

[CJM]

Your welcome, good luck.