Is my exhaust broken?

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RichUK
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Is my exhaust broken?

Postby RichUK » Mon Jul 08, 2019 11:22 am

I noticed my front pipe was blowing so just now removed the bolts at the header and the thing at the top is not connected to the pipe. :shock:

The bit I've circled in red - should this be fixed to the header or loose?
Image[/url]

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No. 47
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Re: Is my exhaust broken?

Postby No. 47 » Mon Jul 08, 2019 12:57 pm

Should be rock solid - if the clamping bracket is tight, the header pipe is likely to have cracked around the collar as mine have twice....................................
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
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RichUK
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Re: Is my exhaust broken?

Postby RichUK » Mon Jul 08, 2019 1:18 pm

So what now, remove and get welded or is it a new pipe needed?

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Re: Is my exhaust broken?

Postby No. 47 » Mon Jul 08, 2019 1:30 pm

Had mine welded.
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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RichUK
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Re: Is my exhaust broken?

Postby RichUK » Mon Jul 08, 2019 1:52 pm

I've just flexed the header out and could remove the end part and can see where it has cracked and let go.

We have a place in my town that do exhaust welding so I suppose I'll remove the pipe and take it to them.

Any tips on getting the system off?

I have the front clamp loose, the whole studs came out so just clean up and re-use or replace?
Will the exhaust pipe to head gaskets be ok to re-use or are they replace each time item?
How about the graphite one on the rear (re-use or replace)?

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No. 47
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Re: Is my exhaust broken?

Postby No. 47 » Mon Jul 08, 2019 2:04 pm

Not sure about SD but for SDR, best way for me has been to remove the whole lot starting with the silencers - best to replace cylinder head and graphite seals ( and isolation washers to support bracket under the engine, if SD is same as SDR) if only 'cos, if you don't do it now, you'll have to remove/loosen off the whole system again when they do go...........................best also to replace copper nuts on front studs (you may have to angle grind/split off current ones on studs) with lots of copper slip or similar on threads.
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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RichUK
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Re: Is my exhaust broken?

Postby RichUK » Mon Jul 08, 2019 2:35 pm

So get the copper nuts off and replace but re-use the studs, I guess I'll see how the studs look after I get the nuts off them.

Replace all 3 gaskets and isolation washer thing (mine looks pretty crushed and knackered now anyway).

It'll also be good chance to clean & polish that pipe, or have it coated... 8)

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Re: Is my exhaust broken?

Postby No. 47 » Mon Jul 08, 2019 4:53 pm

Had mine satin chrome plated here https://dougtaylor.co.uk/
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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RichUK
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Re: Is my exhaust broken?

Postby RichUK » Mon Jul 08, 2019 7:24 pm

How are they holding up?

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No. 47
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Re: Is my exhaust broken?

Postby No. 47 » Mon Jul 08, 2019 8:00 pm

Not fitted yet......
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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RichUK
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Re: Is my exhaust broken?

Postby RichUK » Thu Jul 11, 2019 7:06 am

Got the bugger off!
I did it in the wrong order but still managed it with the help of a second pair of hands to keep it still whilst I wiggled the rear pipe out - that graphite seal did not want to give.

Image

Image

Will be setting off for the exhaust shop soon to see what they can do.

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Re: Is my exhaust broken?

Postby AGRO! » Sat Jul 13, 2019 12:55 am

Should have got a jap bike..... :roll:

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RichUK
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Re: Is my exhaust broken?

Postby RichUK » Sat Jul 13, 2019 7:14 am

Yup..., that CB1000r I almost bought is still laughing at me. :wink:

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RichUK
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Re: Is my exhaust broken?

Postby RichUK » Sat Jul 13, 2019 9:49 am

Just picked the pipe up from the exhaust shop, pretty happy with that.

Image

Ground out the inner before welding and even managed to put three fillets of weld on the rear face to reinforce it a little.

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RichUK
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Re: Is my exhaust broken?

Postby RichUK » Mon Jul 15, 2019 9:03 pm

Almost refitted the pipe this afternoon. :mrgreen:

I offered up the pipe but decided the 'Y' piece is likely in the wrong place, and the tail pipes have never sat equally either so I decided to take them off first.
The rest of the afternoon was spent convincing one of the Akra's the part company with the 'Y' pipe. :roll:

Anyway... that's now done and the pipes have had a bit of a clean up.

Will try again to finish this job tomorrow.

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RichUK
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Re: Is my exhaust broken?

Postby RichUK » Wed Jul 17, 2019 9:00 am

Got it all back together and had a quick ride to meet my good lady for a pint.

It's definitely quieter at the front now, and there is no popping on decal anymore, but I didn't get her maga hot.

What is interesting was looking in the exhausts ports, you can see (i think) where the front has been cleaned by the air coming in. I wonder if it was flaring where the fresh air was meeting any unburnt fuel.

Image


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