Exhaust gasket - vertical.....

[ataDude]

... I know more than just a few of you have had the gaskets replaced on the exhaust vertical joints. I'm joining your ranks.

I searched and have the BRP part number (707600337) but have two other questions...

1. Did anyone ever come up with the Kawasaki part number that fits? I believe that was Sopher's fix.

2. Does anyone have the ID and OD of the gaskets? Maybe you have a spare sitting in the garage you can measure? Reason: I have some Yamaha Warrior gaskets which appear to be close but can't be sure until I tear the Spyder down and... don't want to tear it down until I have gaskets in hand.

Yepper, I know it's warranty but I'm doing this myself. I want to see what it will take to make dual... one on each side... pipes. Thanks!

For you visual folks, they're #8 below:

 

[ataDude]

Shameless bump.

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[bjt]

Whoever had his dealer find an alternate gasket, he never came back with the replacement part number. I don't know the ID or OD of the gaskets either. Guess I'm of no help.....

 

[ataDude]

You're good for moral support, Brian. Moral support. :yes:

Whoever had his dealer find an alternate gasket, he never came back with the replacement part number. I don't know the ID or OD of the gaskets either. Guess I'm of no help.....

 

[ataDude]

Well, I just ordered the BRP parts... upper (vertical) gaskets and the lower one, too, just in case.

Upper - 707600337 (old number)

Lower - 707600350 (old number)

BOTH had been superceded with replacement part numbers. So, that means to be prepared for a failure of the lower one also.

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[bjt]

Possibly. When my dealer replaced my two bad gaskets, they replaced the other one also, "just in case".

 

[smokster]

Possibly. When my dealer replaced my two bad gaskets, they replaced the other one also, "just in case".

How did you know the gaskets were bad?
Was it just louder?, or could you smell more exhaust than usual?

 

[ataDude]

Smokster... in my case, I put the quiet Warrior pipe back on last week for a while (it's still my favorite). I could immediately tell it was louder... from the engine area.

I rode it for a couple of days and it became louder as miles were added. In addition, some backfiring was noticed on Saturday... which was new... but typical for sucking extra air into the exhaust system. I may not have noticed it as much if I'd left the somewhat louder dual Supertrapps on.

It was kind of like a 1948 Ford tractor, if you know what I mean...not a pleasing sound at all.

The gaskets should be here by Wednesday/Thursday. I went ahead and ordered springs, too, just in case. There was at least one instance of the springs being worthless after the gaskets failed.

BTW, I'm reasonably sure (99%) it's not the lower gasket as it was replaced last week with the muffler change-out. It could always be the head gaskets but there is no history there. I haven't taken it apart yet... wanted to have the gaskets in-hand before I did that.

BTW2... I'm still stumped as to why the gaskets are designed for 12,000 (give or take) miles. I've never had a bike with limited-life exhaust gaskets. That's why I was interested in the Kawasaki gaskets. If the Yamaha gaskets I have fit, I'll use those first... they are pretty stout... and designed for the serious thump of a 1700cc twin.

How did you know the gaskets were bad?
Was it just louder?, or could you smell more exhaust than usual?

 

[bjt]

I found out the same way ataDude did, I put on a quieter muffler (stock) after having a louder one (Hindle) on and there was very little difference in noise levels. Plus there was quite a bit of popping / backfiring with either exhaust on. And the coup de gras, when I had it in for the 6,ooo mile service, the service manager immediatlely noticed that I had an exhaust leak.

After they were confirmed to be bad but before BRP shipped the upgraded gaskets, I got quite a bit of heat up by my right thigh by the seat / side panel transition. Also, when I had the panels off, I noticed that some of the heat insulation material up by the tank and air filter housing looked like it was getting a bit more heat than normal.

 

[ataDude]

Updates...

...

1. Yamaha Warrior gaskets won't fit... approx 1/8" too small.

2. The new BRP stock gaskets measure 1.710" ID and 1.920" OD right out of the package.

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[ataDude]

Final...

... the right side gasket was blown into multiple pieces. The left side was still intact. While I had it mostly apart, I went ahead and installed the Evoluzione sway bar. More on that later. And, yes, you can put it on without removing the trunk.

But... the clamps on both sides were loose. I'm thinking (1) that there is an assembly problem, not gaskets or (2) the actual pipe diameters at the joint (upper and/or lower) on the right side are out of spec. If it's the latter, I expect to see another blown gasket in a few thousand miles.

I believe all that I've heard about so far (15-20 instances) have been on the right side... and they use they same gaskets on both sides.

My suggestion: check the exhaust clamps' tightness the next time you have the plastic off... or ask your mechanic.

Right:

Left:

 

[mike3069]

I found much the same thing. My right side went at about 3000 miles. Nothing left but pieces, clamp very loose. Left side started leaking at 8000 miles. Still intact but clamp loose. Tightening the clamp on this one did not stop leak.

My conclusion is that the loose clamp is a result of the gasket wearing. It may be that if you keep an eye on these from the start, and tighten them up at least at every oil change, you may be able to at least prolong the time before replacement is needed.

 

[ataDude]

Hey, Mike. I fully understand that the right side clamp would be loose after losing the gasket. However, the left side (intact gasket) was the one I was concerned about... very loose... even though no apparent wear.

Compared to the Yamaha gaskets I happened to have as a result of buying some Warrior exhausts, the construction is very different.

1. The BRP gaskets appear to be very thin "screens" impregnated with lots of "sealant". Once the sealant is burned off, there is very little left.

2. The Yamaha gaskets are very thick/dense wire mesh covered partially on the outside with just a little sealant. On these, the wire mesh appears to be the primary sealer and the "sealant" appears secondary.

I found much the same thing. My right side went at about 3000 miles. Nothing left but pieces, clamp very loose. Left side started leaking at 8000 miles. Still intact but clamp loose. Tightening the clamp on this one did not stop leak.

My conclusion is that the loose clamp is a result of the gasket wearing. It may be that if you keep an eye on these from the start, and tighten them up at least at every oil change, you may be able to at least prolong the time before replacement is needed.

 

[mike3069]

Humm. Do you have a new BRP to compare to the left (intact) gasket? I am waiting to pick up my new one next week so I haven't seen one yet.
I figured it has to be fatter than what is left over now, but I haven't been able (and won't for a couple more weeks) to actually put new & old to a comparision.

 

[ataDude]

I think I was wrong...

... I have re-thought the tightening mentioned above after reading an article yesterday in Cycle World about exhaust systems, spring retainers, etc.

I now believe these gaskets / joints were designed to be somewhat "loose" as a "buffer" between the rubber-mounted engine and the solid frame-mounted muffler.

There has to be some "give" or flexibility in the exhaust SYSTEM or we will be pulling the headers from the heads (worst case), or blowing the exhaust manifold gaskets at the head (best case). The only ways around this problem would be (1) to mount the muffler to the engine case itself... which is not practical... -or- (2) to have a solid mounted engine which would then increase vibrations to the rider.

Snug 'em up but don't over-tighten!

 

[Greg H.]

speaking of exhaust gaskets.....

... this past Thursday afternoon shortly after my 104mph blast down I-40, I stopped to fuel up. And, I swear when I pulled up to the pump, my Spyder was loader than it was before. And, it seemed, as I sat there listening, the sound was more forward, not so much from behind.
It then occured to me that possibly, a gasket was blown. At speed, I really don't notice too much. But, I think the Spyder is now louder than it was before. Idling in the garage, and when I stand next to it, and roll the throttle, it really does seem loader. I don't notice any exhaust fumes, however.
But, today, I was out for a 65 mile ride, and while on some back roads going slower, I heard a backfire. Yesterday, we had a 188 mile ride down in Mississppi. And, I mentioned to my wife that I think an exhaust gasket was blown. She thought it sounded louder, as well.

As I am getting ready to buy a Hindle, I guess I can address the bad gasket at that time.

 

[ataDude]

Yepper, sounds like it. BTW, I never had additional "gas" smell... just noise. Make sure your dealer orders the new gaskets... there's an upgraded replacement for the original number.

... this past Thursday afternoon shortly after my 104mph blast down I-40, I stopped to fuel up. And, I swear when I pulled up to the pump, my Spyder was loader than it was before. And, it seemed, as I sat there listening, the sound was more forward, not so much from behind.
It then occured to me that possibly, a gasket was blown. At speed, I really don't notice too much. But, I think the Spyder is now louder than it was before. Idling in the garage, and when I stand next to it, and roll the throttle, it really does seem loader. I don't notice any exhaust fumes, however.
But, today, I was out for a 65 mile ride, and while on some back roads going slower, I heard a backfire. Yesterday, we had a 188 mile ride down in Mississppi. And, I mentioned to my wife that I think an exhaust gasket was blown. She thought it sounded louder, as well.

 

[Greg H.]

Yepper, sounds like it. BTW, I never had additional "gas" smell... just noise. Make sure your dealer orders the new gaskets... there's an upgraded replacement for the original number.

I guess there's no harm riding around with a blown gasket in the meantime. :dontknow:

Kind of odd to me, that it's happened to quite a few of us, already.

 

[ataDude]

...Kind of odd to me, that it's happened to quite a few of us, already.

Worse... all on the right, too... I think. Twilight Zone stuff.

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[LDFIREWORKS]

how many miles do you have and when have they been going bad on everyone else?????? thanks