Rear Exhaust header break

[petejr52]

I have a 2003 RK and just went over 50,000miles. Just back from a trip down south I realized the rear header pipe was almost broken all the way through. The little piece from the bracket broke off allowing the pipe to vibrate to excess. Can this pipe be welded and if so will it hold once back on the bike?

[Dave63]

Originally Posted by petejr52

I have a 2003 RK and just went over 50,000miles. Just back from a trip down south I realized the rear header pipe was almost broken all the way through. The little piece from the bracket broke off allowing the pipe to vibrate to excess. Can this pipe be welded and if so will it hold once back on the bike?

If it's metal, it can be welded. If the welder is worth his weight in salt, he can make it stronger then original.

Did it break on the right side, right where the rear pipe feed into the front pipe?

[petejr52]

Thanks for the feedback. It broke up near where it goes into the head, about two inches back.

[Jacket4256]

if they are older and/or stock and it broke where dave is asking than its kind of a common thing kinda like head bolts on shovels I think

[chris_lacey]

I had the same thing on my '94. I welded it several times, but it always broke a little further along. I ended up with a Thunderheader, but there are also repair sections that turn your factory pipes into a true dual set up. It uses most of your existing pipes and mufflers.

[Badassbrutus]

Check your brackets it broke for a reason pipes are not made to just hang off the heads.

[SCHMIDTYS]

Originally Posted by petejr52

I have a 2003 RK and just went over 50,000miles. Just back from a trip down south I realized the rear header pipe was almost broken all the way through. The little piece from the bracket broke off allowing the pipe to vibrate to excess. Can this pipe be welded and if so will it hold once back on the bike?

50k miles ... that's a bunch of rear tires ! Next time you get a new rear tire watch the mech , most likely he'll take out the 2 rear muff hanger bolts and crank down on the muff to get the axle out , that's a no-no cause it stresses that cross over pipe and eventually it cracks and finally breaks . That broken bracket would be the one that is bolted to the starter plate and that breaks when the mech cranks down on the muff .
Get a new crossover pipe and tell the service guys you want the muff removed next time you get a new rear tire .

[Blackdog 15]

I weld them all the time...best weld process for it is TIG (Heliarc).... I use stainless steel filler rod..very forgiving and flexible to avoid further cracking...and fix the broken bracket or mount..no weld can overcome a bad mount...

[Bigdaddyota]

Yeah, just recognized more vibrations and hot fuel gas on inside of my right leg. The header pipe is cracked about 5 inches long and direct after the head. And yes; the bracket screwed on to the starter is broken were connected to the left rear pipe. I had changed all Engine mounts earlier this year - reason: Vibrations and reason therefore: a finally found loosen Crank Sprocket wheel fro the Primary chain. So i believe that gives you potentially some more indications where to look for. I have 36 k mls on this bike and had no mechanic Problems before.

[Bigdaddyota]