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Exhaust header leak,looking for fix tips...

  • Thread starter Thread starter Mr.Mom
  • Start date Start date
Its always something. The other one is hard to get to because the frame bar is in the way. Not sure how I'm going to drill a hole in the center of the bolt.
 
The ones behind the frame are often the ones that break for some weird reason.
I'd use one of these - I have similar, this is just an illustration of what's available. http://www.amazon.com/s/ref=nb_sb_noss_2?url=search-alias%3Daps&field-keywords=flexy%20drill%20drive
I have a small Makita battery drill that's very slim, too. Old but good in this tight situation.
<edit>
Just refreshed my memory by having a look at one I'll have to do - the forks will be off when I do it, so it's much less hassle. It looks as though I'll not be able to get to this one with a slim drill (#3 bottom bolt) as it's too tight next to the frame tube, but a long cobalt drill will do the job.
Example: http://www.phantomdrills.co.uk/shop/product/cobalt_long_series_drill_bits_(hss-co)
 
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Thanks grimly for the ideas. I ended up getting a Irwin 6" bit extender for under $4. So far I am 1/3 through the bolt.
 
Any ideas how to get a bolt out that won't budge with an extractor? I drilled all the way through the bolt, used the extractor and the extractor broke off. Drilled the extractor out...now what?

Thank you:eek:
 
The exhaust bolt with a hole in it. Right at the very end the drill wobbled and the first thread got all fudged up.
 
If it were me I'd get some lefthand drills and go up small increments until the remains of the bolt unpick.
The extractor coming out was a dodged bullet - forget them.
 
Mr.Mom said:
Drilled the extractor out...now what?

Thank you:eek:
Click to expand...
Drill through with a slightly larger drill. If it gets thin enough it will start to move. If you are careful to keep it straight any small damage can be dressed up with a tap. The left hand drills are an extremely good idea, will probably catch and screw the the rest out when it gets thin enough. Might be a good time to try out SeaFoam Deep Creep and let us know how it works.
 
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Well looks like it will have to be retapped. Any suggestions on this as far as size etc.? Should I use a heli-coil instead?


Thank you
 
I would chase the threads with the same size tap and see if it will hold your bolt before going up a size or using a heli-coil. Heli-coils come with their own installation problems, and you would probably need to use two. Using a larger bolt might require drilling the flange clamp ears a little larger, but all three methods will work. You are just dealing with two bolts I believe, so I would at least try chasing the threads before the other methods.
 
Hi,
Got the heli-coils in! Most likely didn't save any money over a shop after all the running around and buying parts/tools I didn't have. Put two in one hole.

Now how the heck do you get out those exhaust gaskets!...?

Thank you
 
Mr.Mom said:
Hi,
Got the heli-coils in! Most likely didn't save any money over a shop after all the running around and buying parts/tools I didn't have. Put two in one hole.

Now how the heck do you get out those exhaust gaskets!...?

Thank you
Click to expand...

Can't put a price on knowledge and skill.

Love a happy ending.

As for the exhaust gaskets, they just come right out?
 
A small angled pick will remove the gaskets. They unravel when you catch them right. I got a set at Lowes. It also had one that is a 3/4 circle on the end that works like a champ removing the clips on the rear brakes.
 
Getting the gaskets out is usually a piece of cake. I just take a small flat screw diver and poke it in the center and push it to the center of the hole. The gasket will just curl in and come right out. Just try to not gauge the head.
 
Mr.Mom said:
Hi,
Got the heli-coils in! Most likely didn't save any money over a shop after all the running around and buying parts/tools I didn't have. Put two in one hole.
Click to expand...
Excellent! And now, the next time you come across similar, you'll breeze right in, with no fear - until it bites you on the ass :D
 
Got the bike put back together. Runs smoother with the new intake o-rings, but
I still get a poppity pop from the exhaust, even with 2 gaskets squeezed down @ 12 ft/lbs. At certain rpms the exhaust gets noticeably louder, as if some of it is coming out the front instead of the muffler. I suspect at certain engine pressures the exhaust is blowing past the new gaskets on one or more pipes.
I am using gaskets from Z1.

Any advice for stubborn exhaust leaks?

Thank you
 
Are you sure you got all of the old gasket material out? The bore recessed in the heads is quite well defined when clean. I just ask because those old smashed gaskets look like part of the head until you get them cleaned out and learn better.
 
Did you take the new seal and match it up to the header pipes? Curious if they match up in size. My seals were slightly larger on the ID that the ID of my pipes. And it didn't seal properly.

Still waiting for my new Cu seals. Should match up better once crushed.
 
Cleaned them out well.


No I didn't check the i.d.:-\\\ Put them in the head and they fit snuggly and looked like they covered the old marks. I suppose I should check the i.d.

Thank you.
 
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