New Zard Exhaust

[ctrain]

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.  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?

[mookieo2]

It might be running lean with the new free flowing exhaust.

Did you put in new exhaust gaskets?

[ctrain]

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.

[He Man]

its a copper washer IRRC.

on my stock exahust, someone..uhh Goldcoast motorsports left it out. 

[mookieo2]

You can get them at any dealer for like $2.

[ctrain]

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.

[booger]

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.

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.

[ctrain]

...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...

[booger]

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.

[corey]

wow.i must have got lucky on those header tube gaskets... leak free on my s2r800 after zard install...

[hunduc]

on the web: ducati omaha, oem number 0370.84.005 is the gasket. 2 bucks.

[desmoworks]

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!).

[ctrain]

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!  

[WhiteStripe]

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

[mookieo2]

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.