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How do you install the Crossover Pipe? What am I doing wrong?

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Old 10-22-2015, 01:02 PM
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Default How do you install the Crossover Pipe? What am I doing wrong?

I replaced my crossover gasket and clamp. My Crossover is still leaking. What am I doing wrong?

I put the clamp on the pipe first, gasket onto the header, then slide the crossover onto the gasket/header. Then torque the clamp to 30ft-lb.

When I look at new touring model at the dealer it seem like the clamp almost flush to the end of the pipe and crossover it over the header shoulder.

I have been check my exhaust system for leaks when cold by spraying the exhaust first with soapy water, Then using a glove and covering the muffler opening. Then I see bubble blowing from the connection.
 
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Old 10-22-2015, 01:14 PM
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I put the gasket inside the crossover, expand it with my thumbs, then slid it over the header. It's a PITA for sure...
 
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Old 10-22-2015, 01:17 PM
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Originally Posted by Joe12RK
I put the gasket inside the crossover, expand it with my thumbs, then slid it over the header. It's a PITA for sure...
Do you clamp it down before the shoulder of the header, on or after?
 
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Old 10-22-2015, 05:11 PM
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New or used clamp? You are tightening it on the low side of the required TQ. Try 45-50 lbs. That might be just enough to seal it up.
 
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Old 10-22-2015, 06:09 PM
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According to the Service manual it says
Muffler Exhaust Clamp 38-43 ft-lb
Crossover clamp 25-30 ft-lb

I don't want to screw up the clamp again.
 
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Old 10-22-2015, 08:21 PM
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Originally Posted by dproto09
I replaced my crossover gasket and clamp. My Crossover is still leaking. What am I doing wrong?

I put the clamp on the pipe first, gasket onto the header, then slide the crossover onto the gasket/header. Then torque the clamp to 30ft-lb.

When I look at new touring model at the dealer it seem like the clamp almost flush to the end of the pipe and crossover it over the header shoulder.

I have been check my exhaust system for leaks when cold by spraying the exhaust first with soapy water, Then using a glove and covering the muffler opening. Then I see bubble blowing from the connection.
That exhaust has to go somewhere. If it takes putting your hand over the muffler outlet in order to get bubbles, there may not be anything wrong. Can you hear a leak? Can you put your hand near it and feel a leak? If you get nothing more than a few bubbles with your hand over the muffler outlet, I don't think you have a problem.
 
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Old 10-23-2015, 06:55 AM
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Maybe your right, I was having some popping. The Service manual said to cover muffler opening, then listens and feel for exhaust leaks.
 
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Old 10-23-2015, 10:26 AM
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Originally Posted by dproto09
Maybe your right, I was having some popping. The Service manual said to cover muffler opening, then listens and feel for exhaust leaks.
Have you driven it to see if you still have the popping? A leak, big enough to get the popping, will be apparent without using soapy water, imo. I had popping on my 02 and it was at the small crossover on stock pipe by the clutch cable inlet, the pipe had rotted through so I put on a take off set of head pipes I got from a friend-- popping gone. My bike had over 50k when that happened though.
 
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Old 10-23-2015, 02:04 PM
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Originally Posted by dproto09
I replaced my crossover gasket and clamp.
I hope i haven't been screwing up things, but what gasket?
 
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Old 10-24-2015, 09:01 AM
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Originally Posted by dproto09
Do you clamp it down before the shoulder of the header, on or after?
I have a fuel moto header so I can't answer that. But it goes on about the depth of the gasket.
 


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