Author Topic: holeshot touring exhaust fitment problems (Read 3345 times)

sahtt · « **on:** May 04, 2006, 03:58:49 AM »

I've had the holeshot 'on' for about 2k miles. When I first installed it, I didn't use any gasket material and it worked great for about 3 months. It became loose between the header convergence and where the holeshot pipe attatched. I could feel slight amounts of gas hit my fingers when revving it.

Fast foward to now, I've reinstalled it about 6 times using gasket maker. It now has a huge leak I cannot figure out how to resolve. It is primarily [only from what I can tell] from 'under' the exhaust pipe, as in under the slip-on there is significant exhaust gases escaping, it is killing my low end.

Also, related or not, the exhaust can has actually scratched my swingarm to the point it is concaved a couple milimeters, the exhaust is also badly scratched now, from the pipe vibrating against the swingarm/frame.

I didn't realize this until the 1st time I had to reinstall it. I bought it used with no directions, and would have never fathomed I'd need them, but I suppose I was wrong.

Anyone have this exhaust and can give me a clue as to what I'm doing wrong? I'm getting the exhaust far enough into the header as to there is a maximum of a few mm's it could pushed in further.

A picture of how it is supposed to look [specifically the amount of space between the frame and exhaust] would also be helpful. Thanks guys, it is my DD and I am wearing a hole into my frame!

kedeg_97B12 · « **Reply #1 on:** May 04, 2006, 09:55:14 AM »

His directions state that it doesn't need to be pushed all the way in. I too rotated the pipe too far around and it wore a divit out of the swingarm. Just rotate it around until it clears the swingarm and the footpeg (so you don't feel the vibrations) and use a permetex ' ultra copper' high temp sealant. Regular RTV doesn't work too well. Sand the old rtv off first with 200 grit sandpaper and make sure the pipe isn't ovaled anywhere.

sahtt · « **Reply #2 on:** May 04, 2006, 04:39:01 PM »

That is interesting. I have been focusing on getting the exhaust in deep as possible ever since I reinstalled it. Perhaps the bend of the pipes won't sit flush by design if you try to force it too far. I've been using the same gasket that I used on the waterpump on my car, perhaps the 400 degrees or whatever isn't quite enough, I'll try the copper stuff even though it'll probably be 15 bucks for an oz stick.

kedeg_97B12 · « **Reply #3 on:** May 04, 2006, 04:50:58 PM »

I don't know where you live (you haven't filled in your location)

but this can be bought for $6.00 at any auto parts store. I actually got it at AutoZone. That is the stuff Dale recommends and sells on his site. It is good to 700*
Click below:

http://www.shop.com/op/aprod-p23920423-k24-g4-~Permatex+Ultra+Copper+High+Temp+Silicone-nover?sourceid=3

sahtt · « **Reply #4 on:** May 05, 2006, 04:57:56 AM »

I overestimated the cost, you are right, it was only 4.99. The smaller bottle of less heat resistant permatex I bought before was 11.99. Picked up some 180 grit on the same aisle to get it done right for the last time hopefully.

sahtt · « **Reply #5 on:** May 06, 2006, 05:14:28 PM »

That didn't work as I expected. Due to the support 'ring' of the right passenger peg, no matter what I do the exhaust is within a mm or so of the frame. What the hell am I doing wrong, this is really irritating me. Does anyone have some pictures to show how it is supposed to be setup? The bolt you use to tighten the exhaust into the header is also stripped, I guess I'll have to ride the busted ass bike to the store to get a new one. I had food poisoning thursday night and haven't eatn in 2 days now, not much patience for experimenting left in me.

kedeg_97B12 · « **Reply #6 on:** May 06, 2006, 07:32:55 PM »

Quote from: "sahtt"

That didn't work as I expected. Due to the support 'ring' of the right passenger peg, no matter what I do the exhaust is within a mm or so of the frame. What the hell am I doing wrong, this is really irritating me. Does anyone have some pictures to show how it is supposed to be setup? The bolt you use to tighten the exhaust into the header is also stripped, I guess I'll have to ride the busted ass bike to the store to get a new one. I had food poisoning thursday night and haven't eatn in 2 days now, not much patience for experimenting left in me.

I stripped the bolt as well, I went up to the hardware store and matched one up.

terrebandit · « **Reply #7 on:** May 06, 2006, 11:42:51 PM »

Why not buy a new donut gasket? that will seal everything up perfect.