Bonneville America Forums Forums Technical Forums General Tech Header bolts and gasket

I noticed a peeking noise yesterday on my 02 BA and when I was checking out to see what it was when I got to work I finally noticed air was blowing around the exhaust. I had mentioned before I was wanting to replace the header bolts because they were pretty rusty and my first question is, do I have to get these thru triumph or are they a common part? My second question is there was only a copper gasket between the header and the engine, is this the way it's suppose to be and is the gasket also something I have to get thru triumph? Thanks in advance, all info will be greatly appreciated

1. What's a "peeking noise"? You must have been in a huge noisy city in China.
2. The bolt is just a threaded stud, available in other places*
(please notice the asterisk, it's there for a reason)
3. Yes, the washer is a copper crush washer and is available from Triumph, but check the Tech Vault 'cause I'm thinkin' you can get a gasket from other bike makes.
4. the asterisk "*" since you're gonna get a washer from Triumph, you may as well get a set of studs as well. And no forget the anti-seize lintiment.
5.

Thanks. I was wanting to go ahead and get new studs and nuts while I was at it. They are in pretty rough shape and want to elimanate any future problems

If you are worried about the amount of rust build up, get some penetrating fluid and spray the nuts liberally. Let the stuff work overnight. Then get a good socket and work the nuts loose then retighten the header with new nuts. You should be able to seal that leak. You can also remove the copper gaskets and reuse them. My headers have been off and on many times using the same copper gaskets, studs and nuts. Mines an 03.

Is there only suppose to be a copper gasket? Mine looks like its been smashed from being put in wrong

I got the gasket ordered but I'm having trouble findin the nut and stud

McMaster-Carr

check over the 'ears' on the header pipe. they have been known to crack or break as the end of the header pipe is a stainless casting. If a repair is needed it can be welded.

Thanks for the info everyone. I check the pipes already, I had thought at first that's where the leak was coming from. I ended up calling triumph and ordering the studs because all my searches came up empty. They won't be here till about this time next week

If the studs are tight in the head, I wouldn't change them. May cause more problems getting them out of the head. Just my opinion.

Got her all back together now and just waiting to get a torq wrench to tighting everything down correctly. I couldn't resist starting it up for a minute to see how she sounds and thing she sounds a lot better now. Now if I can just resist going for a ride before I get that wrench lol

Ok I got everything replaced. The first time that I start it up for age minutes just to see own it runs and no leak. A couple of hours later I go and get on it and make a trip to town which is about three mile run a couple of errands and I start hearing the noise again so I pull over and check and sure enough she's leaking again. I come home and put the ratchet back on the them again just to be sure everything is tight. I start it up and still have the leak. I have repeated the above several times and still have the leak. Today I go and take everything back off to make sure I hadn't already blown the gasket and it looks fine. I put everything but the silencer on and start it up and still have the leak. I did feel around to pinpoint the leak from the begining and its actually coming from a few inched away from the block. I guess it's called the exhaust manifold but its where the the header pipe is welded on to it, there is aguess its a heat that is welded over the most of the area covering the weld between the manifold and header pipe. Anyways there is a small hole in it and the exaust is coming thru it. I check the other header pipe and its set up the same way with the same hole put its not leaking. My original thought before I replaced the copper gasket was there a hole underneath that shield somewhere but everyone that looked at it was oh no it's a blown gasket. So I'm asking for any ideals or agreement with what I think and thinking its a whole under that shield and that I just need weld that hole?