Leaky SRX exhaust connections

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rx1jim

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Feb 17, 2008
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Poughquag, NY
Has anyone found a reliable, long-term material or method for getting the exhaust connections on an SRX seal leak-tight?? I installed brand new exhaust donuts on both ends of each of the 3 pipes. The 3 manifolds were ceramic coated and I polished the inside of the pipes and silencer to make sure they were free of exhaust deposits. I applied a light coating of high temperature orange silicone sealant (good for an intermittent high temp. of 650 degrees F) on the pipe connections prior to installing the pipes. This method has produced connections to the silencer which are leak-free. The pipe to manifold connections were leak-free for about 400 miles then the orange silicone burned off and the leaking began. A light coat of oily exhaust deposit under the connections. This stuff makes a mess of a nice clean engine pretty messy fast. Thanks!!
 
I know what you mean.I had 1 leak bad and made a mess inside the bellypan after I cleaned everything up good.So far I have used the copper sealant and seems to be working so far.
 
Blue, you say you are using copper sealant. Are you referring to the silicone sealant which has copper in it? If so, that is the same material I have tried without success. It is a pain in the %$# to clean up this oily mess after every ride.
 
Have one of you or anyone ever try the black silicone SLP recommends on their pipe installation? I haven't tried it yet but they make it sound pretty good.
 
Hey I had the same problem.

It ended up being at the silencer connections. They were not adjusted properly to allow the pipe to come back far enough on the engine if that makes any sense. You can loosen the factory clamps at the silencer end and move them up on the pipe more. This will allow the pipe to come back more which tightens up the front at the exhaust manifold connection with the springs.

You should have zero play when this is done and fitted properly as it WILL have a great seal with the donut gaskets.
Hopefully this makes sense.
 
rx1jim said:
Has anyone found a reliable, long-term material or method for getting the exhaust connections on an SRX seal leak-tight?? I installed brand new exhaust donuts on both ends of each of the 3 pipes. The 3 manifolds were ceramic coated and I polished the inside of the pipes and silencer to make sure they were free of exhaust deposits. I applied a light coating of high temperature orange silicone sealant (good for an intermittent high temp. of 650 degrees F) on the pipe connections prior to installing the pipes. This method has produced connections to the silencer which are leak-free. The pipe to manifold connections were leak-free for about 400 miles then the orange silicone burned off and the leaking began. A light coat of oily exhaust deposit under the connections. This stuff makes a mess of a nice clean engine pretty messy fast. Thanks!!
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Did you let it set up overnight before putting heat/pressure to it?

I put new donuts on my sled this year (dry) and have not had any leakage but I've also reused the old ones in previous years (the pipes come off every year) and the copper stuff seams to work the best. I've used the black stuff on SLP pipes that use rings to make the seal to the outlet pipe and it also worked well. I also bang and tap lightly on the pipes after all the springs are installed just to help it settle into it's natural position before the sealant cures.

Sounds like you made sure the sealing surfaces were clean and dry so the only thing left would be if it wasn't allowed to cure before putting heat and exhaust pressure to it. At least that's the only time I didn't have success.

Either that or maybe you have an excessive amount of clearance between the seal surfaces in one area which is too much for the silicone to make up for.
 
i used permatex ultra black. it has held now for about 250 miles. i need new dounuts but am cheap so i built up all around the dounuts with this stuff and it works so far.
 
Good to know, I have ordered the permatex ultra black from slp few days ago. I am having the same leaks on a Polaris I own. I am also doing an overhaul on my viper 02, it is clean now and want it to stay clean :).
 
I have been using the Permatex ultra copper sealant. I have also let the sealnt cure for at least 24 hours before starting the engine and applying heat to the joints. I used a new tube of sealnt and it does cure. I just cleaned up the joints and reinstalled the pipes and donuts with the ultra copper sealant. I'll see how well they hold up on my trip this weekend. Thanks for all the replys and good info.!!!
 
Is rich as you had that fuel jim your bound to have leakage,now that you cut back and leaned out it should be better.
 
Daman, very good point. I have just completed servicing the sled: rebuilt cahincase and ALL service items checked and performed as needed. I adjusted the oil cable to 22 mm (it was 18 mm, very oil rich!!!!) cleaned and adjusted the power valves, serviced the drive axle and jackshaft bearings, We are ready to go!!! I sealed the pipe connections with a light coating of ultra copper sealant. All I need is for the trail conditions to hold up in northern NH.
 
Daman, will do!! I am SURE the chain tension was fine before I rode the SRX on the last ride!!! I just after 6 sleds and about 40,000 miles of riding I was due to have a chain wear out. I will post the results of my trip (as long as the conditions hold up!!)
 
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