Fixing Header Exhaust Leak

[jdrouin]

I have the exhaust pipe (short English model, no PAV) off the Bullet right now because I'm fixing an exhaust leak where the header pipe fits into the head. Going to use Permatex Copper gasket maker to seal it.

I've never done this before, so I'm wondering how you guys would recommend I de-coke and clean the mating surfaces of the exhaust port and header pipe.

Once those are clean and dry, I figure I'll apply the gasket maker generously inside the exhaust port and around the top inch or so of the header pipe, and then re-insert it.

Also, it seems like I might want to remove the brake pedal to make it easier to slide the pipe back on, but I'm not entirely sure how to do that. I undid the screw that tightens the clamp and there are these weird nipple-like things on the ends of the bar that I've never encountered before (on machines, anyway).

Many thanks for any tips you might provide.

Best,

Jeff

[Chuck D]

Hi Jeff,
Fine steel wool and some kerosene and elbow grease should clean up that area nicely.
The permatex copper works pretty well but allow it the full cure time. I'd say wait 24 hours before starting up the bike.
Getting the brake pedal out of the way will obviously help. Just take off the adjusting nut from the back of the rod and slide the rod out from the actuating arm, freeing up the linkage and allowing the brake pedal arm to just flop down out of the way.  Unhook the little spring that pulls the brake light switch as well.
Those weird nipple like things are grease "zerks". You attach the business end of a grease gun to them and fire away.
Chuck.

[jdrouin]

Thanks Chuck! I used some generic O'Reilly's degreaser I had lying around and it worked well. Dry steel wool was actually pretty effective at removing coke before I even applied the degreaser.

My only concern now is that I might not have used enough gasket maker to form a seal. We'll find out out when I start it up on Monday.

Jeff

[Chuck D]

Thanks Chuck! I used some generic O'Reilly's degreaser I had lying around and it worked well. Dry steel wool was actually pretty effective at removing coke before I even applied the degreaser.

My only concern now is that I might not have used enough gasket maker to form a seal. We'll find out out when I start it up on Monday.

Jeff

Oh, really?

[jdrouin]

Boy, I did a terrible job. Started the bike this morning and apparently there was some wet sumping. White smoke came out the tail pipe on startup, but also at the header where I just tried to fix the leak. Smoke out the header never happened on wet sumping before.

Unless anyone can tell me the gasket maker will give off smoke the first time it gets hot, it looks like I have to try again.

[ERC]

You'll have to try again. Remember let it dry at least 24hrs.    ERC 

[jdrouin]

It dried for almost 48 hours, but temps here got down to the 50s and 30s. The Permatex tube says ideal temp is 70.

I think I placed the gasket maker poorly. I put some around the inside lip of the exhaust port, where the header pipe would land if it went in all the way, as well as around the pipe at about 1/2" from the opening.

I don't think the pipe went in all the way to the lip, so that bead was simply wasted. Now I'm thinking I should line the exhaust port near the outside opening and the pipe near the end, so the gasket maker comes into contact with itself at the beginning of fitting the pipe. Maybe if the two rings of wet gasket maker meet as the mating surfaces move past each other, they'll form a better seal.

Any advice or experience here would be much appreciated. Thanks!

Jeff

[baird4444]

I always wiped both sides with rubbing alcohol to remove any oils at all. then ran maybe a 1/4" bead around the edge of the pipe. When inserted it just smears down the edge to fill. Then smooth joint when tightened. If none on outside I'd run a small bead round WHOLE circumference. Must let dry for 24 hours...  might consider a light to warm and help cure.

[barenekd]

The white smoke is probably condensation in your pipe. Very common in cold weather. Sump oil is normally blue/grey.
If you're pipe is that loose in the head, get some aluminum exhaust tape at your auto parts store and wrap the pipe with a layer or two until you get a snug fit.
Bare

[ERC]

Put the pipe in as far as you can get it then mark it. Then when you put it in with the sealer you'll be able to tell if it will hit the sealer or not. You'll have to get all the old stuff out because silicone won't stick to itself.     ERC