Exhaust bolt torque?

[ExceptionallyStrange]

TL:DR version - If I over tighten on the exhaust gasket, are they useless and need to be replaced?


I installed a new full exhaust system. At the time I admittedly didn't know there was gaskets that sat inside where the exhaust pipes are received, so I installed the new exhaust without putting in new gaskets. I wasn't positive I had an exhaust leak until a more knowledgeable friend pointed it out to me and told me I needed to replace the gaskets.

I bought new gaskets, replaced the old ones and installed it last night. However after tightening down on the exhaust bolts (as much as I felt comfortable doing without a torque wrench or knowing what torque settings I should be using) and starting the bike up it's still leaking exhaust, probably more so now than before replacing the gaskets.

Today I looked up the torque settings for the bolts and according to this https://www.manualslib.com/manual/791753/Suzuki-Gs500-F.html?page=14#manual they're only supposed to be 7ft-lb! I know for sure I tightened way over that (I'm pretty sure the bolts needed more than 7ft-lb to even move it past the first couple threads).

So did I ruin the gaskets? Also the bolts take a lot of force to screw in and can't say for certain they are original as I bought the bike second hand. I'm not sure if I should buy new ones and/or need to re-tap the threads...

[sledge]

Those gaskets rely on an element of compression and clean seats to work effectively. I have found that once used they dont always seal reliably a second time. Effectively........ One shot.

If I were you I would get two new ones, make sure the seating areas are perfectly clean, and torque the header to cylinder flanges up first leaving the other pipe fixings finger tight. This will ensure the flanges are not being held off.

If you are one of those who believe anti-sieze compound is a good idea on the header bolts its vital you reduce the amount of torque applied. If you don't do this the reduction in friction between the male and female thread may well lead to a stretched bolt or a stripped thread. Personally I would junk the bolts altogether and instead use studs and nuts but that's your call.