Been troubleshooting my headers leaking for like a week+ now.

Finally got my slip-on welded but when I went to go put the pipes back on the bike, the muffler mount was on the back side of where it mounts to the frame.
Used a little bit of force (but not really that much) to get it to the outside of the muffler mount.

Would ride normal for a little while.
but then after a few hours, would hear FARRRR more noise from the headers and ALOT more popping from the exhaust at any decel at any point in the throttle.

after a few rides I noticed some soot on the header pipes indicating what I suspected. (header leaking)

Yesterday I got impatient not being able to ride until a replacement stock exhaust comes.
So I fiddled with it and it seemed to be good for awhile riding.
Until I hit the highway.
Had some bogging like it was fuel starved at certain throttle points.
and then got louder with a little more popping on decel again.
but I dont think there is any soot on the headers this time (gotta go look again to make sure)

So, what are all the possibilities that could be wrong?

Already have a stock replacement exhaust inc as soon as im givin the total price if it is my current exhaust.

Could one of the pipes have gotten bent when I slightly pushed the muffler out to the outside of the mounting bracket?

Maybe the pipe is partially clogged on the inside where it was welded?
as it has gotten ALOT louder then before the weld.

the header mounts where the bolts go through on the pipes are funked now?

valve check already?
did a valve check when I got the motor and put on probably 1500 miles'ish since then.
when I adjusted the valves, the one was at like .07 and the other a little looser then that.

the exhaust gaskets are brand new.

and prior to it acting up and headers getting louder.
When I would stop for a smoke, would hold the cigg near both headers and revved the motor.
didnt show any signs at all.
but that was prior to when it acted up and after it did, was late, dark out and heading home.

tnx

Ok other then another valve check, im stumped.

Just got back from the store (in the car) but checked the header pipes before I left.
Still nice and clean.

Not a single bit of soot.
which makes me assume, even at 50+ mph at higher rpm's, that its not leaking. (was before this most recent adjustment tho)

So a valve clearance check tomorrow and see if anything is partially blocking the exhaust.

other then that, im totally stumped.

Well, (as per my video) I find you need to check the header bolts often after replacing the exhaust headers. The gaskets squish down and the bolts work loose.  I lost a header bolt on Junior a week after we put him back together. Today, a week after replacing the exhaust on Phenix (and oh what a sweet exhaust that Motad is!) the bolts needed re-tightening.

To make it easy, I gave up on a standard allen wrench. I have a #6 ball end allen for my socket wrench.

I tightened them up before today's 50 mile ride. I'll check them again tomorrow and again and again until they stay tight.

I guess anti-seize really keeps them from seizing up and they work loose.

Yeah those are the only allen's I have, the ones for the socket wrench.

but the headers are not loose.

I've had them tight and not so tight with the same results.

theres something other then the obvious wrong, just gotta figure it out.

Hopefully I didnt mess up any of the valves tho when it was leaking pretty badly at the headers the first time I noticed it and rode around for awhile prior.

thats my first check tomorrow.

Did you pit in new gaskets in your header pipes? Did you remove the old gaskets?

Yeah, I think I mentioned I had all new gaskets.

and it was as I figured.
Took the exhaust off and the carbs.
Cranked the motor by hand and all the valves look fine.

took the valve cover off and did a valve clearance check.
All good except the one exhaust valve was at like .03 or .02mm.

Its only been 1500 miles since I put the motor in, so I assume either random occurrence or from when the headers were leaking.
was a 180 in it, tossed a 172 in there and got the clearance to .10mm.

Cranked it some more by hand and looked down that specific exhaust at the valve, nothing appears abnormal.

Put it back together, started up just fine (didnt have a problem with that before tho)

took it around the block.
No Bad decel popping, even when completely off the throttle in 2nd gear at like 5 to 7K rpms.
Just a "Little bit" that is Very hard to notice.

got back, did a compression test... all good!

Since the compression test came back good, Im thinking now the valves didnt get damaged to the point where they would cause a problem.

kk time to shower and go for a test ride to see a good friend that came in from Canada for the weekend!!

If you have been having a exhaust pipe seal leak ,it is probably because you have not tightened them equaliy.
A bit at a time each until you finally torque them up .mine has stainless cap screws which stand up to the heat better.