Loose headers/riding rough

Hey guys I hope you are all doing well. We had a few nice days here in Missouri lately and I was able to get the bike out. I have two loose headers where I can feel the exhaust leaking out around. My question is I have removed and put back on the cooling system so many dang times I would really like to not have to do it again..... Is it possible to reset the headers without needing to remove my radiator? Also it hesitates sometime which I am assuming would be explained by the exhaust leak. They're probably like an 1/8th away from fully seated. Don't know how I overlooked it before I put the radiator back on... I'm thinking maybe unbolt the collector box and try and just wiggle them into place?

Also my front suspension seems a little stiff maybe that's a good thing? If I let out more air it should soften up and take bumps a little less harsh correct?

 

Ryan,

By letting some air pressure out of the forks, you will get a more compliant ride, especially when the fork oil is cold. Keep in mind that you should check the tire air pressure as well.

On the exhaust, you could re-seat the gaskets without removing the radiator. However, it depends on what tools you have at your disposal. It may be worth a try, but if you need new gaskets, you'll have to pull everything apart again.

The stumbling issue could be coming from your exhaust leak, or it may also be caused from a leaner mixture in cooler air. After you get your exhaust leak fixed, and if that doesn't help, try backing out the pilot mixture screws a half turn to see if that does the trick.

Tony

 

To determine if you forgot to tighten the exhaust collars, ... Tape a "Flag" of tissue on the end of a long screwdriver or long dowel.

Probe the Collars with the Flag-end.
If it "Flutters wildly" you have an exhaust leak.
(You should be able to hear it.)

The Collar Nuts :::> MIGHT <::: be able to be tightened by using a 3/8" Flex Extension ...

http://www.matcotools.com/catalog/produ ... EXTENSION/

Or, ... Ratcheting Box Wrench

http://www.amazon.com/Metric-Pcs-Ratche ... B0013VEZ88

 

Stop running the motor until you fix the loose headpipes.

If it's a stock system, your exhaust gaskets may be hammered too thin and need to be replaced. I'm assuming stock since you mentioned a collector box. LOOSEN the collector box clamps prior to trying to reposition the head pipes.

 

It's been my experience that once they are leaking you will need to pull them off, clean up the port and put in new gaskets, but try Rick's method first-you can always pull them off later if it doesn't solve it.

 

I'm firmly against overtightening as a solution to anything. If they're rattling, they're not seated correctly; they still should only need 7.2 ft/lb to be tight.

 

Often, the consequences of having loose Header Collars is that the Exhaust Flange "Donuts" (gaskets) become burned by the exhaust gasses leaking-by and past the reinforced inside diameter, ... scorching the gasket material and rendering the Donut(s) ruined.

 

Wow thank you guys. Rick I do know that they are not seated properly as I can FEEL and HEAR the exhaust coming from the slight gaps. I dont over tighten either. I spend days trying to remove a sheared off header stud. Learned that lesson the hard way....

Looks like I need to remove the cooling system, get new gaskets, (though the ones I put in were the exposure could have been bad for them) and try to put it all back on correctly.

I am going to wrap the headers while I am at it. Any recommendations on a good decent black wrap for the headers? Also someone recommended a different thermostat that opens at a lower temperature for traffic riding that I am having a hard time finding a link to. If any of you guys recall the thread and can share I would appreciate a place to order it.


Thanks guys. I rebuilt calipers, bled my brakes, new brake lines, rebuilt my forks, and learned a ton. I'll get on this. Coudlnt have done any of it without you. Coming spring I am taking a 3,000 mile road trip to Florida to see my grandparents and I dont think it could be done without the assistance this forum has provided thus far.

-Ryan

 

Yeah, sometimes going through the correct way to do repairs can be a PITA, but in the long run the results are worth it.

Here's the forum link on the fan switch mod for the X:
http://www.xjbikes.com/Forums/viewtopic ... art=0.html

Tony