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exhaust pipe gasket replacement

I was forced to run a couple hundred miles with a blown out crossover gasket and my mileage dropped into the low 20's. I am sure air was getting to the O2 sensor and threw the ECU into a tizzy. Point being that would lead to a guaranteed fail of an emissions test.

I'm shocked at the condition of those header studs. Do you keep that thing outside a lot? My 13's with admittedly only tiny amounts of outside exposure in its history has perfect studs that seem to have some plating. Evidently if they are plated it isn't very well.

What do the gaskets look like at the header? I just loosened mine when I did the crossover replacement. There was no need to pull off the header. I wanted to in a way to get a peek but thought it best to leave well enough alone. I was on a long road trip. I suppose they may fail too. Is there a Japanese substitute for those as well?
 
Hi,

The bike is garaged overnight; the exhaust was last removed +- 18 months ago - I was astounded at the level of corrosion myself. I do live on the coast, so I guess it's futile battling nature!

I have come across these guys: https://www.westfieldfasteners.co.uk/ so will look into getting marine grade stainless steel replacements wherever possible.

Surprisingly, a cut-up coke can, some aluminium tape and two hose-clips got the bike through the emissions test. I now have the luxury of time to get the gaskets sorted, but am also thinking "if it ain't broke". The header gaskets were (should be) fine - it's just the crossover. Prevailing wisdom is to regularly check the torque on the clamp (I did not, fair cop).

I've got all the tools I'd need. The question now is hot or cold! If soaking with ATF & acetone - will the solution harm other parts of the machine? And if soaking, due to the position, I guess that means brush on and leave? Lastly - it has to be acetone rather than isopropyl. right?
 
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