Muffler leaking at slip-on...

My slip-on mufflers on one of my 750s are leaking exhaust right at the point of the slip-on, especially the right side pipe.

They fit and are pretty much the correct size, it's just that I can't cram them all the way on due to mount points and the length of the headers. The header is about 2 inches into the slip-on, and the slip-on section is about 3 inches or so.

A noticable exhaust discoloration has built up at that point over the last year or so, making the leak obvious. I can also hear it coming from there under heavy acceleration. It may also be affecting performance (however minor).

Does anyone have a tip (short of welding, which I'd rather not do) of what I might do about this? I thought of three things, and would like advice on any of them (or other suggestions) if your willing:

1.) Replace the headers with longer ones
2.) Cut a slit in the slip-on and clamp around to draw tight to header
3.) Wrap something around the edge of the slip-on to block the leak.. *but what?*

Thanks in advance...

I would try this stuff you can get at any autoparts store. It's called "Muffler Mend". It comes in a tube about the size of toothpaste and is a paste. You just pull the muffler back, coat the end of the pipe and then slip it back together. Just clean up the mess on the outside of the joint with a wet cloth and let it sit overnight before starting the bike. The one draw back is you will have a tuff time seperating that pipe again.goodluck

I've used that Muffler Mender on a hole on the bottom side of my exhaust. It blew out after a couple hundred miles.

I think I remember OKCKent using a mild steel plate over JB Weld to fix holes on his and said it lasts, but that may not be applicable to your needs for the spot around the header.

My manual says to use Super Three Bond No. 10 (P/N 56016-120) where the muffler joins the header pipes. I don't have any of that, but I do use high-temp RTV sealant at the joint. It work OK.
Here's were I'm talking about...

Great tips all around guys, thanks!

I happen to have some of the high-temp atv, so I'll try that first. I don't know why I didn't think of it before... but, that's what this place is all about.

Thanks for letting me bounce it off you...

Isn't there a thin gasket that is inside the joint?

This may sound silly but during my part time duties running network/coaxial cabling when we penetrate a firewall we have to seal the hole with fire caulk. You can get it at Home Depot or a like place. Slap a tube in the caulking gun. Let it dry. Not sure how it would work but might be worth a try.

Post edited by: pumps, at: 2006/08/04 23:44

rgpbeme wrote:

Isn't there a thin gasket that is inside the joint?

These are aftermarket mufflers, and pipes I got from eBay, so there's nothing in there at all.
I still have the original pipes/mufflers that I took off, and I never looked to see what's between there...

you could possibly wrap it with header wrap?? or see if you could stuff some of that in the gap.