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Exhaust Leak.
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hi, i am not mechanicaly gifted  but  l like to have a go now that i cant work.  to drain the transmission on the 94 fat boy i had to move slighty the front exhaust, so i could get to the drain plug , undoing the two nuts that hold it on to the head. after changing oil, and evenly tightning bolts to head , it leaks. tonight i put in the tapered gauze gasket and care fully tightened up the bolts. still  leaks . it should  be a simple job.  any ideas. thanks. RICK
 



 
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Tighten the exhaust system as follows:

a. Tighten the top nut of the front cylinder head exhaust
flange to 9-18 in-lbs (1-2 Nm). Tighten the bottom
nut to 100-120 in-lbs (11.3-13.6 Nm). Final tighten
the top nut to 100-120 in-lbs (11.3-13.6 Nm).

b. Tighten the bottom nut of the rear cylinder head
exhaust flange to 9-18 in-lbs (1-2 Nm). Tighten the
top nut to 100-120 in-lbs (11.3-13.6 Nm). Final tighten
the bottom nut to 100-120 in-lbs (11.3-13.6 Nm)

I don't see why the exhaust had to be loosened,but I might be wrong
 




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pizz - View user's profileSend private messageView user's personal gallery 
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What exhaust system you running Chonppun ??

Is it in the way to remove the transmission filler plug ????

 




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hi, RXES,  yes   the   front cycle shack exhaust is to close to the drain plug  on the side of the transmission,  there is not enough room to get the torx drive in there, thats why even the mechanic who serviced and checked the bike over when i bought it  had to loosen the front pipe  when changing the transmission oil. as i said it was leaking when i tightened it up , taking it off, i found the conical shaped gauze gasket was had it. so ordering a exhast gasket  i put it on ,still leaks. looking at the gasket again i see it is a very poor copy off the original and there is no seat that sits in the head to seal the outer edge of the pipe, that is why it still leaks , i hope. a new better gasket should fix it.  hope alls quiet on the home front.  RICK
 



 
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Sorry for seeming slow chonpuun ..

Is the drain plug on the side & not underneath on your Fatty ??
Or
Are removing the clutch cover on the transmission ??

 




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I had the same problem with one of the bikes I had, could'nt get a torx socket in there

so I cut the torx socket end off where it is the same shape as an allen key and found a

ring spanner to fit the allenkey end of the torx, hope I'm making sense for ya.

I'll go up the shed and find it and put up a photo
 



 
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Post Re: Exhaust Leak. 
 
sam_1898

don't know if you do but
make sure you don't use the hollow torx
 



 
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