Exhaust header gaskets

[sagalout]

I replaced the headers at the weekend with the Keihan ones with the built in link pipe.

I'd ordered some washer/gaskets in advance from Motorworks. I've had these before, and both last time and this time they don't seem to fit all that well. They seem just slightly too big and have to be prised in with a screwdriver, to the point that it slightly warps the washer. When it was all reassembled and torqued up and I started the bike it sounds a bit like it's blowing at ticker and low revs - an extra deep/harsh noise that goes away as revs rise. I can't feel any exhaust gasses at the header or the link pipe, so I'm not sure if it's an issue, or it could be the Akropovic pipe, as I've noticed this noise before with the Akra headers I had on a few years ago.

I guess my question is, should the gaskets be that tight in the manifold, or should the slot in easily? I added a small amount of paste between the gasket and manifold.

 

[Bendy toy]

The original seal washers can effectively vanish under dirt and other deposits. Carefully clean a small area inside the exhaust port and you will be able to see the old gasket edge and then pry in away.

 

[comberjohn]

I used ones from Brooks barn parts on eBay.
Fitted in with no effort. Used very slight smear of exhaust assembly paste to hold them in place until I got the pipes in.
If you had to force them in, I'm suspecting they weren't the correct ones?
Even if you did forget to remove the old ones, the new ones shouldn't be that tight.

 

[sagalout]

I definitely removed the old ones (needed prising out).

These are the ones I ordered (both times)

https://www.motorworks.co.uk/vlive/Shop/Parts.php?T=5&NU=15&M=35&Ct=JA&SbCt=BA_15_35_JA_55

Seems to fit pretty much all BMW twins, including my 2012 TC, so I don't think they could have put the wrong ones in (twice).

For peace of mind I might just get the Brooks Barn ones anyway...I presume its these Athena ones?: http://www.ebay.co.uk/itm/BMW-R-120...aust-Gasket-/331518366543?hash=item4d3008d34f

 

[sagalout]

Also, is the Brooks Barn one for a pair or each? Just noticed it's twice the price of the Motorworks ones - worth it if they fit properly though I suppose!

 

[Bendy toy]

Try tapping the gasket in with a large socket set socket or large washer and a suitable size piece of exhaust tube.

On mine I simply used the old gaskets. If the pipes had leaked I'd have replaced them but they were fine.

 

[Greenman14]

I dod the same as you: Keihan headers and gaskets from Motorworks. The gaskets fitted ok but the exhaust is quite a bit louder and that's with the standard silencer. Are you sure you have a leak? Tissue paper on a stick is a good way to find leaks when it's too hot use your hand.

 

[Bendy toy]

Bung the outlet with a rag. A ticking noise at the cylinder head is likely to be an exhaust leak.

 

[Martyn B]

This is a year-old thread but I'll give it a go. I'm replacing my headers and have bought new gaskets from MotorWorks - is it really necessary to apply gasket sealant to these things? Just trying to save an 18 mile round journey to Halfords!

 

[Sgt Bilco]

This is a year-old thread but I'll give it a go. I'm replacing my headers and have bought new gaskets from MotorWorks - is it really necessary to apply gasket sealant to these things? Just trying to save an 18 mile round journey to Halfords!

No, you will be fine. I've done a number over the years and no problem. Just torque the nuts up correctly.

 

[Martyn B]

Thanks for that Sarge! Now I can't work out how to release the O2 sensor connectors from the plastic socket. Difficult to see lying underneath with the light in my eyes. Any ideas?

NO - HOLD THE PRESS!

Done it - mental note to self, put glasses on!

 

[comberjohn]

Sealant isn't necessary. Only used a smear to stop them falling out while manoeuvring the pipe into place.
You'll see what I mean when you do it. A smear of grease would do the same.

 

[Martyn B]

Sealant isn't necessary. Only used a smear to stop them falling out while manoeuvring the pipe into place.
You'll see what I mean when you do it. A smear of grease would do the same.

Aye thankyou!