Exhaust install help

[wachikinow]

I've gotten plenty of help from you guys already for a few years. Which I thank you for, but I've finally ran into a snag and couldn't find much info on it. So here is my first post.

The bike is a 2009 FZ6R.
I had to replace an oil related part, which required me to remove the (stock) exhaust. Everything was going smoothly, but I cannot get these headers lined up properly to save my life! I just can't get those bastards to go in any further!

I've tried a few times times already thinking "Yes! Finally!", I start her up and by the sound of it I can tell there's an exhaust leak. I gave a small rev to make sure, and she poots herself to sleep.

As for the method I'm using, I grease up the gaskets so they'll stay up in the exhaust port. I have a friend or jack support the unattached muffler while I line up the headers. We jiggle it around to make sure it is surely positioned correctly. Then I hand tighten all the nuts, you know, going a little bit on each one until they're all tight. Then the muffler bolts are hand tightened, and then the header flange nuts are tightened to the 14ft/lb spec.

What sort of tips do you guys have for this?

Thanks a lot, everyone!

 

[Scott_Thomas]

I've gotten plenty of help from you guys already for a few years. Which I thank you for, but I've finally ran into a snag and couldn't find much info on it. So here is my first post.

The bike is a 2009 FZ6R.
I had to replace an oil related part, which required me to remove the (stock) exhaust. Everything was going smoothly, but I cannot get these headers lined up properly to save my life! I just can't get those bastards to go in any further!

I've tried a few times times already thinking "Yes! Finally!", I start her up and by the sound of it I can tell there's an exhaust leak. I gave a small rev to make sure, and she poots herself to sleep.

As for the method I'm using, I grease up the gaskets so they'll stay up in the exhaust port. I have a friend or jack support the unattached muffler while I line up the headers. We jiggle it around to make sure it is surely positioned correctly. Then I hand tighten all the nuts, you know, going a little bit on each one until they're all tight. Then the muffler bolts are hand tightened, and then the header flange nuts are tightened to the 14ft/lb spec.

What sort of tips do you guys have for this?

Thanks a lot, everyone!

When I swapped my exhaust I had a leak the first try and then on second try got it. I pushed them into place and got all nuts on and tightened each little by little making sure each seated. After 2nd try got them to seat. I don't think there's any trick.

 

[bleedinblue]

Take a close look at your gaskets, I could only see it on one or two of mine but you can find high spots on the used gaskets near the edge kind of like a burr.Its where they were never crushed before.Besides from giving you a uneven surface to start with, everwhere except the burr has been crushed by 14ft/lbs, so 14ft/lbs is when the gasket will BEGIN crushing a second time.

Just buy new gaskets they are only around $6 apiece for the oem replacements.If you tried over torqueing to stop your leak and think you might of stressed a stud, they are simple to replace as well.I actually started a thread last week about replacing the header studs, I spent $65 total on all 4 gaskets and all 8 studs with matching nuts.

 

[wachikinow]

Hmmm, okay.
Thanks for the encouragement and advice!

I'll order some new gaskets and give it another go while I wait for them.

 

[JT]

don't get desperate and over tighten them. a few (including my roomate and me) have snapped the bolt doing so lol. definitely a pain in the arse. but you can do it

 

[bleedinblue]

I was just going by google/personal experiences, so I looked it up in the fz6r's service manual to be sure.It says we should use new exhaust gaskets on page 5-2

 

[MistahT]

don't get desperate and over tighten them. a few (including my roomate and me) have snapped the bolt doing so lol. definitely a pain in the arse. but you can do it

Torque to spec. I can't remember what it was, but I think it's only like 30 ft/lbs or something like that, not very tight.

 

[Marthy]

Torque to spec. I can't remember what it was, but I think it's only like 30 ft/lbs or something like that, not very tight.

14 ft-lb. Snug everything not too tight and make sure...

1. Gasket is in place... right place
2. Flange are flat and parallel with the headers flange
3. Torque according
4. I used my gasket in numerous time... there most than likely fine.

Sent from my SAMSUNG-SGH-I337 using Tapatalk

 

[wachikinow]

Yes!!! I freaking got it!!!

I tried my best at not going beyond 14ft/lb, but I did end up bending a couple of the flanges a little bit...

But shes running fine!

Thanks again, guys.

 

[bleedinblue]

Yes!!! I freaking got it!!!

I tried my best at not going beyond 14ft/lb, but I did end up bending a couple of the flanges a little bit...

But shes running fine!

Thanks again, guys.

I'm glad you got it.Did you reuse the old gaskets?

 

[Chris12]

....I grease up the gaskets so they'll stay up in the exhaust port....

Is the grease just the regular old black stuff? Is there anything else that I might use to hold the gaskets in place while the header is fitted?

Thank you in advance!

 

[blkbrd]

Is the grease just the regular old black stuff? Is there anything else that I might use to hold the gaskets in place while the header is fitted?

Thank you in advance!

Petroleum Jelly aka Vaseline.

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[Chris12]

Petroleum Jelly aka Vaseline.

Sent from my SM-G903W using Tapatalk

This was exactly what I ended up using, and it worked perfectly.

I now have a new TBR exhaust installed and it sounds great.

Thanks for the help!