Help/Advise with exhaust donut install

[rbig18]

I just installed the copper donuts from Sledtoyz into my attack. It was fairly simply procedure, although I probably sweated 10 lbs off doing this in my garage here in Dallas. Anyway after installing the donuts on the flex pipes and putting the flex pipes back on I noticed it was difficult to the get the Y-pipes pushed back to perfect alignment with the donut. I could get it extremely close. I mean like 95% perfectly seated into the y pipe. However, after clamping down and starting I "think" I hear an exhaust leak at the donuts. I have the skid out and get under it when running. It sounds sort of like a leak, but I can not feel a leak. I am wondering with the skid out if it just sounds different.

I tried the rag test and it idles down but will not completely stall.

 

[yamadog1]

exhaust

i think you can grind some on clamp to get it tight, not sure someone else will chime in.

 

[Riceburner]

Rag may not work for the test.
I use welding gloves.
U need a tight seal on the exhaust tips.

 

[thor452]

did you check the rest of the exhaust for cracks or leaks? may not be at the doughnuts the flare may not match perfect on the outer most edge but deeper in i bet it is hitting prety tough for it not to seal if the clamps are on straight id check the rest of the exhaust real close they do crack where the 2 go into 1 to go to the silincer.

 

[rbig18]

I checked all along the system for a leak. Did not find anything, if anything it sounds like it is coming from the donut area.

I was going to remove the access panel and start it that way and look for smoke. You can see into it from the side by the secondary.

 

[Crewchief47]

Did you check both flanges for left over Graphite donut? Is it possible that the flange got flat spotted from dropping the pipe or something knocking it over?

The copper donuts are a smidgen thicker than the OEM to help with getting the clamps tight before the clamp bottoms out.

 

[Crewchief47]

Another thought, did the y-pipes feel like the individual tubes were a little too close together to achieve perfect alignment? You may want to try one of those c-clamps that will do inside or outside clamping to manipulate the y-pipes wile tightening the donut clamps.

 

[rbig18]

Thanks for ideas. I order two new clamps today. One seemed just a little off to me when I put it on. Ordered a second just in case.

In the meantime tomorrow I hope to take the gas tank out, pull the shield then pop the gas tank back in and start it. This way I can see and feel both the top and bottom of connection of a leak. If the new clamps don't fix it, I suppose I will drop the whole exhaust end to end and inspect it.

 

[actionjack]

Some have found under close inspection that the flex pipes are cracked. If everything is loose when interfacing the Y pipes with the flex pipes they should seat quite well with a little encouragement. It's not hard to have the clamps slightly mis-aligned. Not many miles on that sled right?

I wouldn't mind meeting the Texas posse next season in QC. You had to get some looks trailering that thing in TX!

 

[rbig18]

If the flex pipes are cracked it is because I cracked them. Everything was fine before I took it apart. I just did it because I get one shot at a trip a year in Quebec and figured get anything and everything that might be about to go done. I guess the old saying don't fix what ain't broke comes to mind.

Love to meet up with your crew in La Belle Province. My handle is "Gas hog" on Quebec Riders.

 

[LJ 452]

When my flex pipes were cracked, it actually sounded ok when the sled was warm, it was when you started it cold that it would either struggle to start, or you could here the leak sputtering out, once it warmed up the sound was difficult to discern. I would check the flex pipes, you can use air, or light and just flex them around to look for cracks. Could also seal one end with your hand and fill it up with water and flex it around. Theses things are very prone to failure, at least in my experience.

 

[rbig18]

Installed the new clamps tonight and same problem. So, got fed up, made new gas lines (longer) so I could actually run it with gas tank out of the way. Voila, found the leak. The right side y-pipe is leaking at both donuts. The y-pipe itself is not cracked, the issue seems to be the end of the y pipe is out of round from being clamped too tight. I am not sure if I am guilty of this or not. How tight do you clamp them down? I went full tight till the clamps could not go anymore. Am I just suppose to snug them up?

Ordered a new y-pipe tonight. If that does not fix it I am going to weld the y-pipe to the flex pipe with a spacer and solve this poor design issue once and for all.

I love this sled but yamaha could not have used cheaper parts in their bushings and exhaust if they they spent 3 years on a walkabout in China looking for the cheapest manufacturer.

 

[thor452]

with stock donuts the clamps go to the stops that are built into the clamps with copper they should get tight before running out of clapming ability if you over do it you can twist the clamps and cause problems. they need to be good-n-tight so they dont rattle loose but not he man tight.

 

[LJ 452]

My guess is that when using the copper donuts, you will have to tighten to "feel". Since the OEM, donuts are able to compress, you can tighten the clamp until the limit is contacted, the copper donuts being much harder to compress will require a bit of feel. I would guess that the copper may anneal after a high heat cycle as well which may require a re-torque, if you were on the low end of the "feel" gauge. I'm surprised you didn't shear the bolt before deforming the pipe. At the very least, I would inspect the copper donuts after the first season of use to determine if the have annealed and allowed the clamp to become slightly loose.

 

[thor452]

My guess is that when using the copper donuts, you will have to tighten to "feel". Since the OEM, donuts are able to compress, you can tighten the clamp until the limit is contacted, the copper donuts being much harder to compress will require a bit of feel. I would guess that the copper may anneal after a high heat cycle as well which may require a re-torque, if you were on the low end of the "feel" gauge. I'm surprised you didn't shear the bolt before deforming the pipe. At the very least, I would inspect the copper donuts after the first season of use to determine if the have annealed and allowed the clamp to become slightly loose.

X2 as a loose clamp will cut a y pipe flange clean off.