Seals - Help (plus unrelated exhaust questions)

[volks28]

Trying to troubleshoot a vaccuum leak. The bike: a 83 GS 850. When spraying carb cleaner around the intake tube, the engine stumbles / sputters and goes back to normal. I read about changing the seals at the intake tubes so here goes:

Took the carbs / airbox out. Wow, pretty easy even for a "two left hand" guy.

I also took the "intake tubes" out to replace the seals. Altough they look fine, I'll replace 'em anyway. Now to replace the studs: what is the size of these stud threads and length (that hold the tubes to the engine). I want to replace them with allen heads

Also took the exhaust off I suspect an exhaust leak. Also pretty easy to remove BUT:

1- four half-moon metal clips fell to the floor. Where do they go and do I need to replace them?

2- What do I need to replace to fix exhaust leaks at the head?

3- The joint at the "front pipe" to muffler fell apart (both sides) The clamps won't keep the pipes secured together (at max clamping) Do I need a new clamp, or something else?

4- Anything else to replace "while I got every part lying on the floor 8O

[beby99]

Also check the rubber on the intake boots. Your leak may
be a result of a cracked boot and not the seal. Take the studs
to your local hardware store and match them up.

[SqDancerLynn1]

Their is an aspestos gasket for the pipes, The exhaust gasket in the head needs to be replaced too you will probably have to dig at it to get it out

[dgeorge]

1- four half-moon metal clips fell to the floor. Where do they go and do I need to replace them?

These go around the two inside pipes where they connect to the head. You can go to www.crotchrocket.com and look at the muffler fiche and see them. If they are in decent shape you shouldn't have to replace them, but if they are like mine were all rusted and pitted you might want to replace them. Crotchrocket lists them for about 1.33 each, and the exhaust gaskets are about 2.70 each.

[bwringer]

Have you seen this yet?

http://bwringer.com/gs/intakeorings.html

Assuming you are in the US, just take your old intake boot bolts to an Ace hardware -- they should have metric stainless steel allen head bolts. The thread is 6mm diameter X 1.0mm pitch, but I don't know how long the bolts are. And I'm not taking mine apart just to see, either!

Have you seen this yet?

http://bwringer.com/gs/intakeorings.html

Here's more info on the o-rings:

http://cycleorings.com/intake.html

[volks28]

Thanks for all your reply.

I "frigged" around with the half-moon clips (header/center pipes) and can't figure it out ( not sure what to put first, and how to orient the clips. The muffler fiche doesn't display these clips, unfortunatly.

I think I have the rest figured out. If anyone has any diagrams that they could share, it would be really great!

1- four half-moon metal clips fell to the floor. Where do they go and do I need to replace them?

These go around the two inside pipes where they connect to the head. You can go to www.crotchrocket.com and look at the muffler fiche and see them. If they are in decent shape you shouldn't have to replace them, but if they are like mine were all rusted and pitted you might want to replace them. Crotchrocket lists them for about 1.33 each, and the exhaust gaskets are about 2.70 each.

[duaneage]

Their is an aspestos gasket for the pipes, The exhaust gasket in the head needs to be replaced too you will probably have to dig at it to get it out

Go to pep boys or any other auto parts shop and get a Permatex Muffler repair kit. It contains enough gasket wrap for two bikes and is the same consistancy and thickness as the original. 3.00 for the package, can't beat it.

[volks28]

Can't seem to remove the old ones (if they are there!)

Any tricks in pulling them out? Are they pressed in?

Their is an aspestos gasket for the pipes, The exhaust gasket in the head needs to be replaced too you will probably have to dig at it to get it out

[dgeorge]

The half moons that you are talking about are #7 in the fiche they go around the #2 & #3 header pipes between the muffler clamp #4 and the exausht gasket #3 with the wide edge towards the muffler clamp I think (not positive on that)

[volks28]

It makes sense now.

They wouldn't really be a direct cause of exh leak (right?)
Because they only "wedge" the pipes between the clamp and the head?

The half moons that you are talking about are #7 in the fiche they go around the #2 & #3 header pipes between the muffler clamp #4 and the exausht gasket #3 with the wide edge towards the muffler clamp I think (not positive on that)

[volks28]

It's all good, I got the exhaust "gaskets" out

Funny thing is, they were doubled! Anyone seen this before?