Last week I spent a night installing a new full Zard exhaust on my 2006 S2R 1000. I love it! But a few things I have noticed...
1. I can hear and feel air leaking out of the pipe where the header goes into the engine block (the header above the swingarm). Each time the piston fires, I can hear a hissing. This didnt happen before with the stock pipes. Ive checked the bolts and everything thing is tight. Should I be concerned or embrace the new sound? :)
2. I feel like its the 4th of July when I start and ride my bike. Popping and Flames! The exhaust pops a bit (which it did before) but now I get a flame that shoots out the back of the exhaust about a foot if its a good one. [evil] Good for getting tailgaters to back off, however, I'm more concerned that it might be ruining the bike. Question again is, should I be concerned or just embrace it?
It might be running lean with the new free flowing exhaust.
Did you put in new exhaust gaskets?
new exhaust gaskets? Um... sure?! ??? :)
Everything the system came with was installed. (header pipe, mid-pipe, cans, and mounting hardware) As for new exhaust gaskets, not sure where those are or what they look like.
its a copper washer IRRC.
on my stock exahust, someone..uhh Goldcoast motorsports left it out. [bang]
You can get them at any dealer for like $2.
nope! Didnt have those. It had a crush gasket for the O2 sensor but not the headers. I have noticed that the engine block has slits in it at the point where the header pipe goes in. It feels like the air is leaking from that point but I could be wrong.
Quote from: ctrain on March 30, 2010, 07:59:01 AMnope! Didnt have those. It had a crush gasket for the O2 sensor but not the headers. I have noticed that the engine block has slits in it at the point where the header pipe goes in. It feels like the air is leaking from that point but I could be wrong.
Well then you need to use new header-to-cylinder head exhaust gaskets. If you were to actually
look inside where the headers mount up to the cylinder head, you would see the crush gaskets. They are difficult to make out; it looks like there's nothing up in there but there is. Get a pick and pull the old ones to replace with new. Alternatively just tighten the header nuts a smidge, perhaps that will take care of it.
Also, the popping and flaming - are you running a stock airbox and ECU? S2R1ks are notorious for fueling issues. Might be that you need to go ahead and get the DP ECU/airbox to round out the fueling.
Quote from: bergdoerfer on March 30, 2010, 08:25:37 AM
...Also, the popping and flaming - are you running a stock airbox and ECU? S2R1ks are notorious for fueling issues. Might be that you need to go ahead and get the DP ECU/airbox to round out the fueling.
Yes, Im running stock airbox and ECU. Sounds like that will be the next mod...
Damn, i have to take off the headers? The back one is a beast to get to...
There is a thingy called a fatduc that costs maybe $40 that might mitigate your fueling issues. Might. Before you go tearing the exhaust down again try tightening the exhaust stud nuts first.
wow.i must have got lucky on those header tube gaskets... leak free on my s2r800 after zard install...
on the web: ducati omaha, oem number 0370.84.005 is the gasket. 2 bucks.
Just to clear it up - the exhaust does not include the gaskets. It is something that either needs to be reused, or replaced (which is my suggestion). With new gaskets you shouldn't have any more issues. This air leak will also be part of the flame thrower and popping on decel issue you have. Fix the leak then see where you are with the air/fuel ratio before taking the next step (as the next step won't be clear until then!).
I think this should solve the problem. It makes more sense now that I think about the process of getting the stock pipes off. It was a BEAST getting the stock rear header off. My guess is with the tweaking and moving around the pipe while still in the engine block, the gasket probably got jacked. I went and picked up some new gaskets today $2.38 at the dealership. Talking to the the shop tech while there this was his recommendation too. Ill put them on and report back. Thanks for the help guys! [thumbsup]
I found a ratcheting wrench made my rear header pretty trouble free. Might be worth checking out.
Also, i reused crush (just left them in there) but did use copper ATV with great sucess. Since you are oulling it back apart can't hurt to spread alittle in there if you didn't.
Zards rock.
Tim
Quote from: WhiteStripe on March 31, 2010, 09:21:37 AM
I found a ratcheting wrench made my rear header pretty trouble free. Might be worth checking out.
Tim
I also use a universal joint with a 2' extension.
If 'm not mistaken, the exhaust to header gasket is a crushable single use thing. Sometimes you get lucky and can reuse it, sometimes not. Also, don't tighten down the bolts until everything else is in place and tightened. If you have to loosen and tighten, same problem happens since it's already been crushed. Cheap to get new ones, sometimes a pain to put them in.
Scott
before you fix this, did you get video [evil]
Quote from: DucatiTorrey on April 01, 2010, 06:10:48 AM
before you fix this, did you get video [evil]
I havent fixed it yet... guess ill be filming tonight. :) ;D
Okay okay, we are talking about the gasket between the MidPipe and the Header Pipe.
I reused mine. Turned them inside out, the worked just fine.
I also slathered them in Permatex Exhaust & Tailpipe Sealant, per recommendation from some other folks.
There isnt a leak between the header pipe and the midpipe. i believe the leak is between the header pipe and the engine block.
Quote from: ctrain on April 01, 2010, 08:49:39 AM
There isnt a leak between the header pipe and the midpipe. i believe the leak is between the header pipe and the engine block.
And this area gets HOT, around 1200F or so. RTV sealant will fail. There are some thermosetting putties you can get but a fresh crush washer is best.
Scott
Well I spent a few hours today putting the new crush gasket on.... and although it sounds better than it used to, it still sounds like it is leaking. I dont feel air like I used to but it still sounds like it is leaking.
[bang] [bang] [bang] [bang] [bang] [bang]
Any other ideas as to what it could be?
might be good advice... heat = expansion... expansion = shit sealing up ;D
When i installed my Arrows something that helped me was to actually measure how far they should seat in. In other words, looking into the female pipe if its 2" in to be full seated, throw a small piece of electrical or ducttape on the male pipe at 2.25". That way you know if they are all the way in.
I found it hard to tell just by eye, and noticed along the way that i needed to go 1/4" more than i thought.
Not sure if this makes sense (or maybe just super obvious), but helped me get the fittament perfect and no leaks. I reused the crush - literally just left them up in there.
Also, i assume you are using some kind of sealant on the non-header joints. I used Permatex Copper RTV. I just pulled my exhaust back apart and was please to see that 2k miles later the sealant was still intact everywhere (left header pipes on so did not check that). Would recommend gooping that in there as well.
Not sure if this is helpful, but good luck. You will get it sorted.
Any update ctrain?
BTW, let me know if you want to go ride (now that I have a bike again), this weekend is going to be gorgeous!