I agree with the previous post - based on the dirt lines, they were (at least at one time) slipped closer together. Once there is no "hole" the leak will be much less noticable but still present - then you can do the RTV thing and be rid of it.

I'll see about snapping a photo tomorrow.

 

Luckily, the silencer never fell off, the mouting bolts just rattled loose. I have the slip on bolted as far forward as possible and I still have that gap. Unfortunately, the silencer can't be adjusted forward much because the mouting holes are prefectly round.

 

Loosen up the two nuts holding the headpipe on, and loosen the bolts for the silencer - now gently rotate the headpipe a bit and see if you can get that gap to close up - I'm gonna put $0.35 on it that it will.

 

Interesting! I never thought of loosening the head pipe bolts. Do those usually loosen easily?

 

Be VERY cautious about loosening the headpipe. I'm not saying don't do it, but soak it in penetrating oil like PB Blaster for a few days, and if it feels like they are stuck, don't try to force them. With all the heat cycles that those studs go through, not only do they get weaker over time, but they also have a tendency to get stuck easier because it's steel-aluminum contact.

 

This would be why mine get loosened / re-tightened at least once per year, if not twice - keeps things a bit more free.

Do lubricate them for a few days and let it soak in thoroughly if you've not had them off before.

 

Thanks guys. I'm kinda on the fence regarding the headpipe. I may try the high temp silicone and the exhaust wrap first.....

 

Bumpin' another old one guys. I'm thinking of using a little header wrap to fix this. Anyone ever tried that?

 

You almost have to loosen the headpipe, IMO. When I was installing my MX4 on the Warrior it won't slip all the way on, I had to have the head pipe loose. Just get yourself some good lube and let sit for a couple of hours and you'll be fine. I would go with high temp RTV and you'll be good to go for the joints.

 

I found some stuff at Advanced Auto called "Muffler Bandage". It was under $2...I'll see if it's worth trying. Allegedly, the heat bonds it to the surface. If I don't go that route, I may just go with some flashing a few stainless hose clamps.