I Have a 2003 sportsman 700. I have run it 2000 miles. Runs great, but lately; in the last 10 hours of use, I notice that as it warms up, it gets VERY loud like open headers and hot exhaust blows on my right calf. I have inspected every inch of the tail pipe, no holes. There is no crack in the block. I see ALOT of play in the manifold where it enters the tail pipe.
Question #1. Can the seal ring between the male end of the manifold and the female tail pipe wear out? (allowing exhaust and hot air to blow back)

Question#2 If there is excessive play with use, will this be enought for me to hear the engine sound much louder and blow on my calf??

Help!
BB

 

I'm not 100% sure but I think it would be yes, and yes.

 

There is a doughnut gasket where the head pipe meets the manifold and there is one where the pipe goes into the muffler.

 

They're both the same exact part. I just don't know why it would wear out unless the play in it caused the wear.

 

Thank you both. I pulled the dougnut gasket and it is pretty thin. I just cannot come up with ANY reason for it to get louder with heat and blow air on my leg with heat in the engine????
I ordered a gasket and I will see how this does.
Any other suggestions are appreciated!
BB

 

Sometimes heat will expand the exhaust and make a slight leak go away. In your case it sounds like the opposite. Either way, its probably just the donut gasket that needs to be replaced. I don't think 2000 miles is that bad at all before having one wear out.