SuzukiSavage.com - Exhaust leak in the middle [stock muffler]

Riddmkidd

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Exhaust leak in the middle [stock muffler]
12/12/25 at 18:42:17

Hi all,

Looks like my clamp at the connector is loose. It's #12 on the diagram. Is there a torque setting for it? Also does it matter which orientation the clamp goes? I've got it rotated for access to it while it's mounted on the bike. Still have a leak, though.

I've got a replacement oem clamp and connector so take 2 when I have time.

Also, thr forward clamp has broken off both rear heat shields! I found a spare on ebay and I swear the tab was on there when it arrived. My original one snapped off before I got it so I'm finally dealing with the issue. How crucial is that clamp? That's just securing the heat shield to the muffler, correct?

I'd like to keep it stock but these circumstances are making a delkevic or dyna slip on pretty tempting.

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Riddmkidd YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 10	Re: Exhaust leak in the middle [stock muffler] Reply #1 - 12/12/25 at 18:42:51 Diagram that didn't get attached...
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Riddmkidd YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 10	Re: Exhaust leak in the middle [stock muffler] Reply #2 - 12/12/25 at 18:43:29 Also photo that didn't get attached...
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18587 Camp Springs, Kentucky Gender:	Re: Exhaust leak in the middle [stock muffler] Reply #3 - 12/13/25 at 06:47:36 Maybe you need a new gasket......item 13 on the parts diagram you showed.
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Riddmkidd YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 10	Re: Exhaust leak in the middle [stock muffler] Reply #4 - 12/15/25 at 14:09:50 huh, here's what I have. this doesn't look the same to me. replaced the clamp and new part doesn't fit as it's the same diameter as the rest of it all. tightened the clamp a couple of times in different places and I still have a pinhole leak. I'm guessing I'm missing some parts?
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Riddmkidd YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 10	Re: Exhaust leak in the middle [stock muffler] Reply #5 - 12/15/25 at 14:16:18 trying again to attach the photo. page says 1.5mb is too big? Suzuki s40 exhaust https://imgur.com/gallery/5rUZsdq
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18587 Camp Springs, Kentucky Gender:	Re: Exhaust leak in the middle [stock muffler] Reply #6 - 12/16/25 at 03:21:21 You need a new muffler gasket. Let me try this another way. https://www.ebay.com/itm/286663017264?_skw=ls650-+gasket+muffler&itmmeta=01KC...
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Riddmkidd YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 10	Re: Exhaust leak in the middle [stock muffler] Reply #7 - 12/16/25 at 23:47:21 That's the same part number in my photo. Couldn't get it to install though. It wouldn't slip on the exhaust pipe. Judging by the diagram it's supposed to go between the exhaust and the muffler and then sealed by the clamp, yes?
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Dave

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Re: Exhaust leak in the middle [stock muffler]
Reply #8 - 12/17/25 at 03:55:59

Riddmkidd wrote on 12/16/25 at 23:47:21:

That's the same part number in my photo. Couldn't get it to install though. It wouldn't slip on the exhaust pipe. Judging by the diagram it's supposed to go between the exhaust and the muffler and then sealed by the clamp, yes?

You have to clean off all the corrosion and old gasket from the header pipe.....smooth enough that you can push the gasket over the header pipe. Then push the muffler on. You can use some anti-seize past to help slide the pieces together.

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Riddmkidd YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 10	Re: Exhaust leak in the middle [stock muffler] Reply #9 - 12/20/25 at 00:14:28 am I correct in thinking the connector is the meat in the exhaust sandwich? exhaust header on the inside, connector in the middle, then muffler flange on the outside?
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Dave

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Re: Exhaust leak in the middle [stock muffler]
Reply #10 - 12/20/25 at 15:59:54

This really isn't as complicated as it seems.

The header is the smallest diameter pipe.

Slide the round gasket onto the header - if it won't slide on you need to clean off the rust and debris until the gasket can be pushed on the header up to the welded on "STOP" that limits how far it can go.

Put the clamp on the muffler - then slide the muffler onto the gasket. (Once again you may need to clean off rust/carbon/debris).

Bolt the back of the muffler in place, then tighten the clamp at the header/muffler joint.

If you need help getting things to move/slide - use some anti-sieze as a "motion lotion"!

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Riddmkidd

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Re: Exhaust leak in the middle [stock muffler]
Reply #11 - 12/20/25 at 16:22:32

i have been wrestling with this thing for the better part of 3 hours. getting the muffler far enough on to the exhaust pipe with the connectors in between is a real pain. also, anti seize lube isn't a good idea. while it helped get the parts together I know have a smoky BBQ going.

the connector is similar to the exhaust gasket in that it is several bands of flimsy material that crumbles up if you aren't careful and pry the muffler tabs wide enough to clear the connector during installation. sheesh.... if the muffler isn't on all the way the foot peg can't be reinstalled. that's how you know you need to pound the pipe into the muffler some more.

I used my drill and an 80 grit sanding disc to get the rust off of the pipe. definitely wear goggles and a mask for that!

documenting all this just in case it helps someone else.

this really makes a delkevic or a dyna slip on seem more attractive.

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Riddmkidd YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 10	Re: Exhaust leak in the middle [stock muffler] Reply #12 - 12/20/25 at 17:18:08 test ride failed...now I have a leak at the header. sigh .. used a new Suzuki gasket too, torqued to 14 ft-lbs since the manual says 13-20ft-lbs. puffs of smoke when I blip the throttle. do I just need to torque higher?
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Re: Exhaust leak in the middle [stock muffler]
Reply #13 - Today at 04:38:54

Riddmkidd wrote on 12/20/25 at 16:22:32:

also, anti seize lube isn't a good idea. while it helped get the parts together I know have a smoky BBQ going.

The anti-sieze is a good idea. It does smoke a bit when fresh - but it leaves behind a coating that prevents the parts from bonding together and helps get them apart in the future.

Riddmkidd wrote on 12/20/25 at 17:18:08:

test ride failed...now I have a leak at the header. sigh .. used a new Suzuki gasket too, torqued to 14 ft-lbs since the manual says 13-20ft-lbs. puffs of smoke when I blip the throttle. do I just need to torque higher?

Do not overtorque the header bolts. If you were pushing/shoving on the muffler/header gasket with the header on the engine - you likely damaged the gasket at the top gasket. Remove the header and inspect the gasket....when you assemble the header onto the cylinder head you need to be sure you are keeping the header seated evenly at the head.

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Riddmkidd

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Re: Exhaust leak in the middle [stock muffler]
Reply #14 - Today at 12:44:54

ok I'll be patient with the smoking and trust the process.

I was working on a thick cardboard box as a work mat and dropping the pipe onto the cardboard on the floor to hammer the pipe into the muffler (gently, I thought). I figured the header pipe is the most delicate part of the system as it has to mate into the engine and gasket. I made sure to tighten both bolts together instead of one at a time too. but I'm clearly not doing something right as I've got a leak. Suzuki Brand gasket as well... I'll remove it and try again.

oh, maybe this is still the same problem: I hadn't got the muffler all the way on the pipe so the mounting screws in the back wouldn't line up. after getting the muffler tabs to line up with the ridge on the pipe it would fit but the footpeg didn't have enough clearance to be mounted because the pipe was still a bit forward of the engine. one more try I guess. I'm word I'm going to break something but I think everything just isn't pushed together enough.

thank you for the advice and insights. I'm learning as I go with this.

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