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Hi there. Bought a 2008 Crf230f a couple months ago. It came with a T4 Pro Circuit exhaust. It had a small exhaust leak at the front flange that I can feel with my hand when running. After some riding today it got worse and sounds awful. Feels worse to the hand as well. I tightened the two nuts which weren’t loose but turned about a full turn with a 6 inch wrench. It seems to have gotten worse.

I’ve attached a couple pictures. Doesn’t look right to me. Spacing around the exhaust flange isn’t consistent, the “insulator” looks bent (flexed) and I don’t see the “insulator band” in the parts diagram at all.

Any thoughts what the fix should be? Thanks, Tony

I will take a wild guess and say the gasket.
Doesn't normally have to be overtight.
In the pictures is the flange actually bent?

See part 2
https://partsfinder.onlinemicrofiche.co ... %20MUFFLER

The pipe doesn't look centralised in exhaust port so check how things are mounted as some adjustment may be required.

Welcome to the site !!

What that looks like to me is a couple things , it looks like the Crush Washer (usually copper and pliable) is most likely missing

It looks like this:


The second issue I see is the flange looks too large for the pipe , the pipe should fill most of that gap , so to me the pipe and flange are not meant to go together .... ... that is what I seeing those pictures ... so yea , something is not quite right ...