Few exhaust question

[Flying96XP]

I know i posted almost the same thing in the X-4 thread but i figured i'd throw it out on the main forum as well. I'm having issues with my head pipe coming loose 3-5 minutes into riding on my 96 XP. I've been through a broken pipe and a few gaskets now. Per some advice i inspected the the mounts and found the rubbers cut up and smashed. I ordered all new mounting hardware and yet another gasket. So my questions are...
1. Is there a washer on both sides of the mount bushings or just the bolt side. Parts image shows just bolt side.
2. what is the best way to sequence the bolts (loosely install all then head-pipe to cone pipe to the mounts on motor to the mounts in pipe?)
3. Locktite? yes or no? red or blue?
4. I just installed a new copper washer between the head and cone pipes with the red high temp silicone. should i replace that again also or should that be fine to reuse?
Thanks for the help!

 

[roneagan@cfl.rr.com]

I have this problem with one of the motors in my sportster. I have 3 ski's and the boat, all have been apart and this one motor is a real pain!!!I have tried a couple of things to fix it with limited results.. I have not been able to try my latest fix, but here is what I did.. I drilled and taped the three bolt holes to 7/16-20, I left the 8mm stud and used a nylon lock nut.. I did try 10mm 1pitch but it came loose again, but had improved.. This time I used the finer thread bolt with red locktight, and I torqued them to 40lbs, the manual calls for 35. I did test the tightness on an old manifold before I did it on the engine.. The bolts are stainless steel alan heads with lock washers, regular head bolts won't fit.. You can get the bolts from McMaster Carr.. I will update when I get chance to test it, last time out I had a fuel problem, so I didn't run it very hard..

 

[Flying96XP]

not going to lie. If i have to go through all that im selling the damn thing. this is my 3rd 96 XP and the first time ive had any sort of issues like this. If that pipe keeps popping off its only a matter of time before the engine burns up a piston from leaning out. had the thing a month and have a total of 20 minutes seat time. :banghead::cuss:

 

[roneagan@cfl.rr.com]

Mine only comes loose if I run it at full throttle, I have had the boat since it was new, my problem only occured after I took the pipe off to fix a leak.. I would try red locktite and be sure to torque the bolts.. good luck..

 

[Flying96XP]

fair enough. hope the bushings, full realignment and red lock-forever-tite works. thanks!

 

[Flying96XP]

pretty much got everything figured out except torque down sequence. Everything will be loosely installed but what should i do first? clamp down the cone/head pipe clamp with the rtv or should i bolt up the headpipe then clamp then mount bolts?

 

[roneagan@cfl.rr.com]

I always bolt the pipe on first, then tighten the clamp..