Crappy exhaust remedy?

Good evening all, I am nearing the end of fixing up an old project '78 kz650b2 but I am stuck with a nasty exhaust leak at the head. A few years back I purchased probably the cheapest exhaust option, the MAC 4-1, to just get the bike road-worthy again. A few years and some(?) wisdom later, I have revisited the exhaust by doubling up on gaskets and layering it all with copper rtv. (I even degreased and lightly wire-brushed the gaskets before the install). This still results in a leak at the head from improper flange seating on my #3 header. Has anyone had any success with the MAC 4-1 exhaust?

I just put a new Mac on my sons 650 I also used two sets of copper exhaust gaskets, left the originals in place and put new ones in front, no leaks, It did leak with just one set of gaskets, I also hate the tinny note it puts out so we are going with an alloy muffler I have spare, just have to sort out a new mid pipe...

I don't know the best fix.  Have you checked the header tips w a straight edge?   
What are the chances a muffler shop could straighten them? (without damaging the surfaces)?

Not saying this is the issue, but some of the aftermarket pipes require a longer or shorter split collars.to make a good seal.  Have also read here and else where that the copper gaskets for some of the Suzuki bikes work better than those for the Kaw bikes. 

 

wrote:

I just put a new Mac on my sons 650 I also used two sets of copper exhaust gaskets, left the originals in place and put new ones in front, no leaks, It did leak with just one set of gaskets, I also hate the tinny note it puts out so we are going with an alloy muffler I have spare, just have to sort out a new mid pipe...
 

Did the mac exhaust for your son's bike accept the oem split collars?

wrote:

wrote:

I just put a new Mac on my sons 650 I also used two sets of copper exhaust gaskets, left the originals in place and put new ones in front, no leaks, It did leak with just one set of gaskets, I also hate the tinny note it puts out so we are going with an alloy muffler I have spare, just have to sort out a new mid pipe...

 

Did the mac exhaust for your son's bike accept the oem split collars?

FYI, the Suzuki exhaust gaskets that were mentioned have a  gasket material in them that is sandwiched between copper.  I tried them on my KZ-1000 but they were too thick for me to get the exhaust nuts started.  They probably would have worked great but unless I install longer exhaust studs I will never know.

Rick H.

Agree longer studs or shorter split collars would be a solution.