Strange space between headers and motor

So I recently removed the 4to1 exhaust that came on my bike and replaced the muffler and wrapped the pipes. When I removed it, it didn't look like the parts diagram in my manual, each header flange had 2 half circle spacers/sleeves between it and the pipe. Don't know if its related but when I went to reattach the pipes today there is abspace between the motor and the end of the pipes. I cant remember if it looked like that before but I cant figure out how to press the headers up against the motor. I got header gaskets from len because there weren't any on when I removed them, but it would take about 3 of them to fill the gap. Its like I'm missing a spacer or something.

 

There shouldn't be any spacers between the head pipe and the gasket. The end of the head pipe should fit tight against the gasket. Don't over tighten the nuts on the exhaust studs or you will bend or snap them off. On aftermarket exhaust systems, the head pipe retaining flange is usually just a flat plate so it looks like there is a gap. On the stock head pipe flanges, the half circle spacers you describe are recessed into the head pipe flange when the nuts are tightened. What you describe as spacers are part of the head pipe that allow the flange to pull the head pipe securely against the exhaust gaskets.

 

Have another look. I'll bet the original old header gaskets ARE there.

 

perhaps but there is still a gap where the headers slide in and out. the flanges are bolted all the way down.

 

pictures would really help man....

 

As zombiehouse said, those half circle flange spacers push the header pipe against the engine. They are necessary to install the exhaust. The ones on my mac 4-2 are two half circles connected on one side, and when the exhaust is removed they like to slide down to the pipe junction.

Are you sure they didn't slide down and you wrapped over them? Where are these spacers now?

You should also fish for those exhaust gaskets. They are likely there, and once you install the exhaust properly, you're going to find that it doesn't fit. BigFitz52 had an excellent thread one this issue (with great pics).

 

ok ill take a look again. and i have the half circles but i thought they went between the flange and the pipe, to keep the pipe from sliding out. There is still room for the pipes to slide in more even with the flanges bolted in. Ill try to get some pictures next chance i get to work on it.

 

So im at work now but thinking back on it i guess i should ask, do those spacers go outside of the flanges, because i had them inside but im thinking it could work the other way. Wish i had paid more attention when i took them off haha.

 

Here is how mine bolt up; also a four-into-one (Gemini) system. The original half-moons are not used.


IMAG0373 by buellosaurusrex, on Flickr

 

They should go outside the flange. If they are inside and pressing the pipe up against the engine (with a gap) then you might have the flanges backward.

The flanges will not be close to the engine when installed correctly, there will be a significant gap between the flange itself and the engine. That's why the exhaust studs are so long.

 

They look pretty normal to me, they do look a little angled too low tho, like the top won't seal. This could just be the angle of the shot tho.

 

Ohhh ok I had the circles in the flange around the pipe. That should do the trick I think then. Ill be back if it doesn't work. Thanks for the help everyone.