exhaust leak
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Road Captain
Joined: Oct 2011
Posts: 523
Likes: 1
From: kingston ontario
exhaust leak
i seem to be having issues with exhaust leaks, i managed to stop the muffler leak but now both headers leak at the jugs. new se gaskets, proper torque....
has anyone ever doubled up on gaskets?
would like to leave using a sealant on the jugs/headers as a second last resort.
has anyone ever doubled up on gaskets?
would like to leave using a sealant on the jugs/headers as a second last resort.
Road Warrior
Joined: Aug 2011
Posts: 1,566
Likes: 2
From: Detroit
The SE gaskets are so thin if the face of your header pipe and the flange of your exhaust port are a little off you will gap and leak. What kind of exhaust do you have?
Honestly if you dont have a big bore with full port and polish heads then using stock gaskets arent going to rob any performance. They always seal, you never leak on stockers unless your flange nuts loosen up.
Problems like this are one reason you need to seat the header and get it dead square in the ports before moving downstream with the bolt tightening. In the end though it could just be variation in the exhaust manufacturing and if its a 2 into 1 they sometimes fight one another on the port fit.
Honestly if you dont have a big bore with full port and polish heads then using stock gaskets arent going to rob any performance. They always seal, you never leak on stockers unless your flange nuts loosen up.
Problems like this are one reason you need to seat the header and get it dead square in the ports before moving downstream with the bolt tightening. In the end though it could just be variation in the exhaust manufacturing and if its a 2 into 1 they sometimes fight one another on the port fit.
i seem to be having issues with exhaust leaks, i managed to stop the muffler leak but now both headers leak at the jugs. new se gaskets, proper torque....
has anyone ever doubled up on gaskets?
would like to leave using a sealant on the jugs/headers as a second last resort.
has anyone ever doubled up on gaskets?
would like to leave using a sealant on the jugs/headers as a second last resort.
Last edited by Motown Strag; Apr 28, 2013 at 07:12 PM.
Road Master
Joined: Oct 2008
Posts: 970
Likes: 19
From: Philippines
I'm running a set of Bassani pipes on my Train. The Bassani's don't allow me to install stock cone shaped exhaust gaskets and I have to use the flat Screamin Eagles. I also had exhaust leaks. Doubling up the gaskets solved the problem.
Thread Starter
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Road Captain
Joined: Oct 2011
Posts: 523
Likes: 1
From: kingston ontario
The SE gaskets are so thin if the face of your header pipe and the flange of your exhaust port are a little off you will gap and leak. What kind of exhaust do you have?
Honestly if you dont have a big bore with full port and polish heads then using stock gaskets arent going to rob any performance. They always seal, you never leak on stockers unless your flange nuts loosen up.
Problems like this are one reason you need to seat the header and get it dead square in the ports before moving downstream with the bolt tightening. In the end though it could just be variation in the exhaust manufacturing and if its a 2 into 1 they sometimes fight one another on the port fit.
Honestly if you dont have a big bore with full port and polish heads then using stock gaskets arent going to rob any performance. They always seal, you never leak on stockers unless your flange nuts loosen up.
Problems like this are one reason you need to seat the header and get it dead square in the ports before moving downstream with the bolt tightening. In the end though it could just be variation in the exhaust manufacturing and if its a 2 into 1 they sometimes fight one another on the port fit.
i tried starting with the headers first but ran into issues with the muffler and mounting bracket lining up right.
i have redone everything several times to get everything to line up properly.
the first time i installed them was with the old se gaskets and i dont think it leaked at the headers but i cant guarantee that.
at this point it may be a little more difficult to redo as i used a sealant on the exhaust union as it was leaking but if i have to take it apart i will.
i am tempted to try the stock gaskets as you suggested with the hopes of avoiding disassembling the exhaust pipe from the headers but i also realize some short cuts are really the long way around things.
if the headers are fighting one another what would you suggest?
i want to make this work
Thread Starter
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Road Captain
Joined: Oct 2011
Posts: 523
Likes: 1
From: kingston ontario
the harley manual also suggested permatex copper if a sealant must be used (must be o2 sensor safe) but i wanted to leave that as a last resort.
its easy to tell the are leaking by the hot air being blown on my hand when placed near by and of course the sound.
what is it about the bassani that doesnt allow you to use the stock gaskets? shape, alignment?
and it is good to hear that some people have had success with doubling up gaskets as it was one of my first thoughts.
its easy to tell the are leaking by the hot air being blown on my hand when placed near by and of course the sound.
what is it about the bassani that doesnt allow you to use the stock gaskets? shape, alignment?
and it is good to hear that some people have had success with doubling up gaskets as it was one of my first thoughts.
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Road Warrior
Joined: Aug 2011
Posts: 1,566
Likes: 2
From: Detroit
Allot of aftermarket exhausts have a thick header flange and with the thick stock gaskets some guys cant get the nuts started on the studs.
As for the other slip joints in your system they will carbon up soon so don't worry too much, you can also add clamps if needed under the heat shield if they continue to leak.
As for the headers you can double up the SE gaskets and they will still be thinner than stock. That might fix it but it depends on how much your header flange is out of square with the port.
A sealant should not be necessary, just bite the bullet, take it apart and reinstall it with either the doubled SE gaskets ($30 for gaskets now) or the stock gaskets. You can re-seal the slip joint when you have it apart if you want.
I know it sucks but if you get it settled in and snugged down it will be fine for the life of the bike or until you take it off aside from tightening the flange nuts once a year.
As for the other slip joints in your system they will carbon up soon so don't worry too much, you can also add clamps if needed under the heat shield if they continue to leak.
As for the headers you can double up the SE gaskets and they will still be thinner than stock. That might fix it but it depends on how much your header flange is out of square with the port.
A sealant should not be necessary, just bite the bullet, take it apart and reinstall it with either the doubled SE gaskets ($30 for gaskets now) or the stock gaskets. You can re-seal the slip joint when you have it apart if you want.
I know it sucks but if you get it settled in and snugged down it will be fine for the life of the bike or until you take it off aside from tightening the flange nuts once a year.
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Supporter
Joined: Jun 2012
Posts: 2,912
Likes: 73
From: Pittsburgh, PA
Even the stock gaskets can be a tight squeeze getting them in without deforming.
I just put a dab of the Permatex Copper on my finger and just lightly coated the outside of the gaskets.
After that they pretty much just slid right in.
I did the same on the inside once they were seated, just a light coating.
I even used a clean rag and wiped off any excess.
Like anything else, just take your time.
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