Downpipes.. Old ones off - cant get new Motad ones on

[Andy Smith FZS]

Posted a thread before about my downpipes as they were a pain in the arse to get off.

Got my new rad pipes fitted (thanks again chris) 
The copper gaskets that came with the exhaust dont seem to fit in head very well. 
When I try and line up the exhaust, I only get about 1mm of the stud sticking out.

The old washers were a bastard to get out (copper ones with a sorta metal weave round the side)

I sat the downpipes one of my flowers platers lol with abit of wood for leverage, can use my knee to push the pipes up while I try and slot them into place.
Still no joy. Booked MOT for tomorrow at 2pm so kinda urgent.

Still got to fill up the radiator, put fluid in the brakes and fit my new shinny can.


Plus a trip to yam dealer today because my delivery didnt show up (front res cap screws)

Cheers

Andy

[darrsi]

This is highly unlikely, but of course it happened to me, when i took my exhaust off to renew the o-ring crush gaskets i found two sets jammed in there.
I thought something wasn't quite right until i kept digging and out they popped!  :rolleyes

[Dead Eye]

You have probably tried this, but mine did get a little stuck in places and I just wriggled them and they ended up slotting in properly, it is a bit of an awkward angle. I usually try to loosely fit the bolt that holds the underneath of the pipes to the frame first as this prevents the headers from slipping out of the exhaust ports

[clayt74]

Use a smear of grease to hold the gasket in place.... my motads fitted a treat 

[Fazerider]

It might just be the perspective, but it looks to me as if cylinder 3's gasket isn't seated fully in the recess.

[gerkin]

Use a smear of grease to hold the gasket in place.... my motads fitted a treat 

mine were a doddle to fit as well

[His Dudeness]

You could re-use the old gaskets to get through the mot and sort the new ones out when you have a bit of time

[andy352299]

make sure you have completely cleaned the exhaust port where the copper gaskets sit, I held my new copper gaskets in will a little exhaust paste,
a little bit of fiddling and the pipes lined up, the only issue I had was the where the exhaust went under the engine the centre stand fouled them when being raised and lowered, I ground a little bit (1-2 mm off the stand where it rubbed, job done

[Punkstig]

Wiggle it a bit more!

[Andy FZS]

Why does that sound familiar>

[j the yank]

I recently had to pay some one to replace mine. The old set were the original ones and the bolts snapped and had to be drilled out. Took him 6 hours. Good giggle until I got the bill. I seriously need to but a house with a garage. And more tools. And learn what I'm doing.  :rolleyes

[Dead Eye]

make sure you have completely cleaned the exhaust port where the copper gaskets sit, I held my new copper gaskets in will a little exhaust paste,
a little bit of fiddling and the pipes lined up, the only issue I had was the where the exhaust went under the engine the centre stand fouled them when being raised and lowered, I ground a little bit (1-2 mm off the stand where it rubbed, job done

I used petroleum jelly (Vaseline) to hold the gaskets in place. Since its petroleum based any excess will just be burnt off and the rest gets baked and creates a good seal No trouble removing them after this either (which I've had to do). Wouldn't exhaust paste eventually break down in to a grit / powder?

[Andy Smith FZS]

Downpipes now fitted, still needs tightened up abit.  The two middle downpipes seemed to be slightly too far apart.
managed to get them on with an extra pair of hands and some straps.
I found the back bolt was difficult to get on, as if the downpipes are out of alignment slightly. 
The venom can sounds sweet,  haven't sealed it yet incase I try to re do the pipes.

I used a big socket to get the gaskets in place which helped.  The old gaskets were knackerd and I've cleaned the ports up as best I could.

does anyone have any tips for routing a 2 line set up for the front brakes.  I fitted and bled them but don't think there positioned properly.

Cheers

Andy

[Andy Smith FZS]

Some pics of the downpipes.  don't think the pics of the headers are of much use.
the other on shows the bolt at the back of the exhaust isn't straight.
haven't put the nut on the other side to tighten it but a guess that might pull it into place.. 

[Andy Smith FZS]

No2

[Andy Smith FZS]

No3

[Dead Eye]

The 3rd is nothing to worry about, its just the weight of the pipes pulling on the bolt - gravity is a b!tch

I do see what you mean about them sticking out a little from the head - have you had her running to see if you have any leaking? If there's no leak from the headers then I wouldn't worry about it

[Andy Smith FZS]

I did have her running, just slipped the link pipe on and my new exhaust without sealing them and it sound amazing but i couldn't feel any leaks.  I read that new pipes can sounded abit tinny so I might be that and the smell of burning wd40.
Is there an easy way to check for leaks without roasting the crap out of your hand!

[paul1606]

Fitted motad ss headers to a cbr 600 i had once they too were a bit of a bugger to fit (didnt line up properly) eventually had to "tweek" the misalighned pipes with a pry bar & bits of wood so i didnt damage them ,once fitted they too were off a little on the under bracket just used a spacer in the end the can will twist and line up ok

[bandit]

A hand held folded length of kitchen towel around the ports.