[steves]

"extremely tight" isn't torqued....

[brez24]

I ordered new gaskets. I should have them by Monday. Hopefully that will solve the problem. The bolts I have in now are much tighter than the ones I removed when I took the stock header off.

[ctandc]

I ordered new gaskets. I should have them by Monday. Hopefully that will solve the problem. The bolts I have in now are much tighter than the ones I removed when I took the stock header off.

Can anyone actually confirm whether or not the exhaust manifold bolts are different lenghts on the pre-98 vs. post-98?

I checked online and they are different part #'s, but that really doesn't mean anything.

If the bolts you used are too short, they might not be catching enough thread to pull the flange tight...

[brez24]

Can anyone actually confirm whether or not the exhaust manifold bolts are different lenghts on the pre-98 vs. post-98?

I checked online and they are different part #'s, but that really doesn't mean anything.

If the bolts you used are too short, they might not be catching enough thread to pull the flange tight...

I had the stock bolts as tight as I could get them and the flanges were still able to wiggle. I came across this thread and it worked for me.

http://katriders.com/vb/showthread.php?t=63252

[brez24]

OK, I put the new gaskets on and tightened the bolts properly. The bike sounds great (never noticed how loud the actual engine was). Now I can't keep it running w/o leaving a little choke on or constantly revving it. Even after it's been running for over 10min. Could the air flow have changed from the old header to the 98+? It will also rev up and down at some points on its own.