Exhaust clamp cracked

[Harold_Boom]

Hi all,

I was fitting the exhaust back on after Charlie fixed the turbo and the exhaust clamp cracked. It wasn't even that tight as I have the crush exhaust gaskets in.

https://imgur.com/a/Af3hpiD

My question is, can I still use it or will it leak? Also if I need a replacement, does anyone make them?

Thanks

[ptremb]

Theoretically it should be replaced as you won't get even crush on the gasket. Should be readily available on ebay. Not sure if they are still available new.

[Harold_Boom]

Thanks mate, managed to get some from eBay. Any idea what torque they should be tightened too? I can't find it in the manual.

I was tightening evenly across the two bolts per clamp.and working my way back and forward across clamps until they were the same distance in on the stud. 1 or 2mm from the end and bang

[JezZedexE1]

When you are putting it all back together, make sure the half-moons are seated correctly. I have seen a few over the years that are somewhat bent, suggesting they were not seated properly and have been bent during assembly. I use a bit of masking tape to hold them in place.

Page 1-11 of the Turbo supplement. I have used this torque guide/list where possible. If any one item is not listed then refer to the basic torque for general fasteners list. Being 8mm nuts, that suggests 14-19 Nm; 1.4 - 1.9kg/m; 10/0 -13.5ft/lb. Please check and confirm, as I do not want to be responsible for any damage through misleading/incorrect info..

You can probably ignore the COOLING SYSTEM figures.

[Harold_Boom]

Thanks mate, yeah I had a look and it looks like 20nm max. I don't think I would have got it that tight. Maybe like you said the collar might have been seated incorrectly.

I will tape them in place next time to be sure. Cheers

[JezZedexE1]

working my way back and forward across clamps until they were the same distance in on the stud. 1 or 2mm from the end and bang

Bear in mind the studs may be "different lengths" or protruding out of the head more or less than the next one, so they may not necessarily be the same distance in to the stud. Hope that makes sense.

[Harold_Boom]

working my way back and forward across clamps until they were the same distance in on the stud. 1 or 2mm from the end and bang

Bear in mind the studs may be "different lengths" or protruding out of the head more or less than the next one, so they may not necessarily be the same distance in to the stud. Hope that makes sense.

Yep makes sense, didn't even check that. I will measure them this time. Don't want anymore stuff ups haha

[Kawadoodle]

Reconnecting headers is always a pain. I always recheck and straighten the colletts. I always make sure the studs are good, a new nut should spin on by hand without binding, otherwise the studs are stretched and if so carefully need replacing. I always use new stainless nuts. With the clamps slid on the header tubes, I put paper tape on the colletts to hold them in place, i dont remove it, just allow it to burn off when the engine is run. I use a some grease to retain the gasket seals in the head exhaust ports. When I secure the clamps I keep an eye on the gap from the back of the clamp to the head whilst tightening the nuts, keep the gap even at both studs. I don't tighten down the nuts fully until I'm happy everything is evenly seated. Although text book to torque, I prefer to finally tighten but feel, but that's experience of feeling the resistance from the gaskets as the collapse.

[Harold_Boom]

Thanks for the tips mate, I was wondering how people got the tape off. I guess you live and learn. Not a cheap mistake but it won't happen again

[750turboguy]

I just wanted to chime in here with my story. Yeah, those fucking things are a pain in the ass to get on...holding all those pieces while trying to get my nuts on. Pain in the ass!


I learned to smear all the pieces with grease to hold them on and then let the grease burn off.

You should be able to find those on ebay. Where do you live? Are there any cycle salvage places around? Walk in with one and I'll bet you they have a box of them in the back somewhere.

You can probably still run the bike but be gentle because it'll probably "puff" a little bit.

[Harold_Boom]

Managed to get some from eBay, yeah what a pain in the ass. I also think the gaskets I got are too thick so I got some thinner ones and some new nuts.

Second time lucky hopefully! Got lots of tips which will make it much easier