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Old 01-03-2010, 10:41 AM   #1
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On my '96 T-cat I'm having a problem with an exhaust leak comming from where the pipe fits into the manifold. I already tried replacing the carbon ring that goes inside the manifold but it did not help at all, if anything it made it worse. Is there anything I could use that would seal the connection? I've tried hi-temp sealer but since everything is rusty regular silicon won't stick to it and just blows out. Any help would be greatly appreciated, thanks.
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Old 01-03-2010, 11:06 AM   #2
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Either the flanges on the pipes or manifold coulb be bent or damaged, or possible the springs are weak and worn and not holding enough tension.
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Old 01-03-2010, 11:18 AM   #3
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<div class='quotetop'>QUOTE (zrt600trip @ Jan 3 2010, 12:06 PM) <{POST_SNAPBACK}></div>
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Either the flanges on the pipes or manifold coulb be bent or damaged, or possible the springs are weak and worn and not holding enough tension.[/b]

x2, you could also try if you haven't already cleaning everything with maroon scotch bright pad. and then use the copper atv.
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Old 01-05-2010, 09:24 PM   #4
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This problem is a pain in my ass too. The 96 has the worst design going. I have yet to figure out how to fix it. I got new springs too. I was just about to order those little gaskets that go in there. Those are alot more expensive than they should be. I will hold off since you said it did not help at all.
I am very interested to see what others have done to overcome this problem. Mine is on a ZRT
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Old 01-05-2010, 09:39 PM   #5
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I say put new springs on all the tabs and tack weld each exhaust port just to hold them together, then remove the whole system and finish welding it all together....It wont ever leak again.............
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Old 01-08-2010, 05:17 PM   #6
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<div class='quotetop'>QUOTE (arcticcatmattt @ Jan 5 2010, 10:24 PM) <{POST_SNAPBACK}></div>
 Quote:
This problem is a pain in my ass too. The 96 has the worst design going. I have yet to figure out how to fix it. I got new springs too. I was just about to order those little gaskets that go in there. Those are alot more expensive than they should be. I will hold off since you said it did not help at all.
I am very interested to see what others have done to overcome this problem. Mine is on a ZRT
[/b]
Problem fixed. I pulled the pipe off and cleaned the ends inside and out with a wire wheel, for the inside you can get a course 1" wheel for a drill at just about any True Value store. I plugged the inside of the exhaust manifold with a towel to keep anything from getting inside the cylinder and sprayed brake cleaner inside that outer manifold flange to dry up any oil inside there cause silicon will not stick if it is oily. After everything was good and clean I squeezed some copper sealer into the manifold where that so-called carbon seal ring goes and also put a thin layer on the end of the pipe itself. The painful part was waiting for the sealer to set-up, in cold weather it doesn't dry very well. I had to wait about two days just for it to become tacky. Doesn't leak at all now.

You might try instead of copper sealer, there are muffler repair paste that come in tubes that you can get at most automotive repair places, but I'm not sure if they are as flexible as silicon. I don't think welding the pipes is a very good idea, no offense, because the pipes need to flex with the tork of the engine and bouncing around during riding. Making them solid might lead to cracks maybe even cracking the exhaust port on the cylinders, especially if you ride a lot of rough trails, just my opinion though.

Sorry it took me so long to post, been out riding, FINALLY. Have a good one.
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Old 01-08-2010, 05:58 PM   #7
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thanks for posting. I have the same problem on my sled. glad I don't have to spend the $$$ on new donut gaskets. $35 a pair from the dealer.
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