Exhaust leak

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smuggler
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Exhaust leak

Post by smuggler »

Hey ,
I just got back from our trip around the lake and the bike ran excellent. But I had trouble with the o-rings at the cylinder head to exhaust pipe. They started leaking again and it sounded terrible. This is the second se of o-rings in two weeks. Could there be something wrong with the o-rings? Or am i missing parts. Two springs and two o-rings?
Thanks
2001 KDX 220
2006 Polaris Sportsman 500 EFI
1996 Polaris XLT SKS
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kdxquebec
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Post by kdxquebec »

Starting point:

Cylinder flange :razz:
Copper washer
Pipe
2 orings
Hi temp (or normal) silicone
2 springs


Sometimes a bent pipe, a worn out cylinder flange or a broken pipe damper mount do not help.
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Post by canyncarvr »

Those o-rings don't generally seal for diddle. As KDXQ said..use silicone at that joint.

(clean it, put a bead around the pipe, assemble. Don't run the bike 'til it cures)

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Post by smuggler »

Thanks guys, I am also missing the copper washer. Not sure where that went. I guess thats what happens when you buy second hand...
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Post by canyncarvr »

IMO and all, but that copper piece needs to be there. Besides its gasket nature, it also keeps the headpipe joint from banging on the cylinder.

Steel pipe, aluminum cylinder...and banging is not a good combination.

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Post by smuggler »

Now I see. ...I love this bike, my wife is actually getting jealous :lol:
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Post by canyncarvr »

Re: 'Not sure where that went.'

It falls out real easy when you're not looking. Then...being round and all, it rolls way far away.....

Get the copper piece, clean up the pipe and the exhaust flange on the cylinder, put some hi-temp gunk on it...you'll be fine.

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Jealous?

Seems you have to Pol-skis. Time to even it up with two KDXs. :wink:

That might keep her busy...you tryin' to catch her!

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Post by smuggler »

Sounds like a plan CC. :wink: Thanks for the info.
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Post by barryadam »

Tip: Put a generous amount of the black stuff that CC showed in the O-ring grooves on the cleaned pipe and then put on the new o-rings. Then re-trowel a nice layer of the black goop over the o-rings.

Put a THIN film of the black stuff on the flat face of the cleaned pipe end and stick the new copper gasket to it. Put another THIN film of the black stuff on the face of the copper.

Slide the pipe into the cleaned port and twist a wee bit. The black stuff will ooze out around the pipe. Leave it as is if it looks OK or form a nice bead around the pipe. The stuff takes 24 hours to fully cure.

Don't put the black stuff in the port and then slide the pipe in. It pushes the excess into your KIPS/exhaust port.

The black stuff will be messy and ruin your clothes, so be prepared. I have a lot of black silicone/never-seize decorated clothing.
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Post by canyncarvr »

Ha! Anti seize...isn't that stuff great! DANG..it does get EVERYwhere....

Re: 'Don't put the black stuff in the port and then slide the pipe in.'

Smuggler...you've read that a couple of times. That's 'cuz it's important!!

Cure tip: Hang a trouble lamp under the joint..it will cure better/faster. It won't cure well at ALL in most Newfoundland ambient temps I'd guess.

And..no...don't use a heat gun.

Do I have to say...NOT an LED trouble light? I don't? Good!

...no CFC pos, neither. An honest to goodness glowing filament just SUCKING the life out of the earth. THAT'S what you need!

:wink:

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Post by smuggler »

Sounds good guys, my garage temp is usually around 70 so it should cure ok...
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Post by Byte »

>|<>QBB<
kdxquebec wrote:Starting point:

Cylinder flange :razz:
Copper washer
Pipe
2 orings
Hi temp (or normal) silicone
2 springs


Sometimes a bent pipe, a worn out cylinder flange or a broken pipe damper mount do not help.
Part number ofr this cylinder flange?

Recommended size O-Rings?

Byte
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Post by canyncarvr »

Re: 'Part number ofr this cylinder flange?'

It is an integral part of the cylinder. There is no separate cylinder flange part.


Re: 'Recommended size O-Rings?

The size that fits.

These aren't o-rings you're going to get from your local hardware store. They are HIGH TEMP pieces. Any bike shop should have them. Order them by pipe type (PC if you have a ProCircuit, FmF if you have one'a them, Domo, DG...whatever.......)

FmF cards spring/o-ring sets for different bikes. No..I haven't checked to find if they have such for the KDX. You can do that.

If you have the OEM pipe..you can look up the KAW part numbers on any fiche site...like I did...and found:

670E3039 O RING,39MM


..for the 'H' series KDX anyway.

RonAyres microfiche listings are not my personal domain. YOU can use 'em too!
Last edited by canyncarvr on 06:15 pm Oct 09 2009, edited 1 time in total.

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Post by Byte »

thanks
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Post by jswag »

my bike(2004 kdx 200) was completely stock... pipe has never been off...it had a washer i guess but it was paper thin and damaged. does the fmf come with a washer and o-rings etc. just curious.... i got the fmf gnarly woods pipe and powercore 2 from rmatv/mx for 312.00 plus shipping.anyone looking for a slightly bent stock pipe and silencer, let me know.
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Post by canyncarvr »

A new FmF pipe will come with o-rings..but I've never seen one come with a new gasket (copper piece).

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Post by Byte »

problems.

I cannot restart my bike now...


I replaced my old fuel with new fuel and it ran Ok straight after I fille dwiht new fuel.

I let idle for 2 mins and then shut it off.

I then could not restart it.

I replaced the new fuel with 40:1.

I do not observe excessive exhaust smoke and hence unlikely to be worn out piston & rings or worn cylinder.

PLease advise my next steps..

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Post by Byte »

Image

Image

Image

Plug is new (no more than 500m) and is NGK BR9EG.

No being an expert on these things, but form these photos, it seems I have not fouled the plug.

I am willing to stand corrected however...

SOrry for poor quality of photos - still leanring MACRO on the camera...

I did not rev it before OFF.

SHould I do this from now on? Purpose of this activity?

Plug is new (no more than 500m) and is NGK BR9EG.

No being an expert on these things, but from these photos, it seems I have not fouled the plug.

Have I fouled the plug?

I have dumped all new fuel from tank and willign to start again...

Should I use 50:1 fuel mixture instead of 40:1?

THoughts?

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Post by Indawoods »

Put a BR8ES in it and be done with it.

Why are you putting a 9 in it? That's a cold plug.

You really need to follow the MANUAL!
Last edited by Indawoods on 08:22 am Oct 10 2009, edited 1 time in total.
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Post by Tedh98 »

I'll try on this one . . .

Your plug looks wet with fuel. Remove the plug, kick the engine over a few times and put a new plug in or dry that one. Then without giving it any gas, try starting it up again.

I had an old kx250 that had a plug that would look like yours. The problem was the float level was set wrong. Once I set it properly, I never had starting problems.
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