[ley700n]

Hi everyone
recently bought a trx 300 needs a little work, one of the issues was a leaking exhaust where it joins the head.
I have a copper gasket from a top end gasket kit installed it but all the mounts are misaligned the exhaust needs to go back 10mm

nothing is mentioned in the service manual so question is -
is trx 300 suppose to have a gasket?
and how much does the gasket crush? enough for the exhaust to realign?
thanks in advance

 

[fishfiles]

Welcome to the forums Ley , which 300 do you have the TRX300FW (4x4) or A (2x4) Fourtrax or the TRX300EX SporTrax

the way I do the copper washer on my 300 FW , put the washer in place , then start all the mounting bolts that hold the muffler to the frame but don't tighten them , tighten the exhaust pipe flange studs till snug but not over tighten , start the engine and let it get hot , then tighten the studs more , after those studs are tight , then tighten the mounting bolts

 

[ley700n]

Thanks for the quick reply fish, i have a 300 2x4

Problem i have is i cant get the mounts in line, i think the copper gasket needs to crush more, didnt think of warming the engine up so will try this now
do you know if the flange is supose to bottom out agains the head? i can tighten the studs more but dont want to over tighten
thanks

 

[fishfiles]

The flange will just about flush with the head , I just went outside and looked at a few of them of all different years

If your mounts are not aligning then you may have the wrong muffler / pipe for your year , there are different mufflers and the mounting holes don't line up and it sounds like that is what you got ---------------- do you know the year ? The 10th digit of the vin will ----------------- post a pic of your bike and the exhaust

 

[ley700n]

Hi Fish took your advice had the engine fired up 1st time since the top end rebuild.
as it was warming up i could tighten the studs more (not over tightening)
and eventualy the flange was tight against the head and the holes aligned up!!

thanks again

 

[fishfiles]

well that is good news , the copper ring is hollow , after it is heated then it bends easily to get flat

 

[SamUK]

well that is good news , the copper ring is hollow , after it is heated then it bends easily to get flat

Never realised they were hollow, learn something new every day.

 

[fishfiles]

funny how simple things get passed by