What's wrong with this picture?

[BigDick]

yeah, I knew I had an exhaust leak for a while now, but I thought it was in the joint where #3 header joins in with the exhaust. Yup my exhaust is completely broke in half.

Is there any reason I can't just take it to an exhaust shop and have them weld it back? Should I just go aftermarket 4 into 1 and k&n pod filters? I don't have experience tuning/jetting carbs. I don't have the money to have a shop do it either, also I have a minimum of tools to work with. If there's a member close by who'll help I may go that route. I think I had read somewhere on here that the 4 into 2 stock exhaust was ideally tuned/set up to provide the best hp/torque, any truth to that? One last thing, should I worry about plugging/covering the exhaust ports since I have the pipes off? The bike is outside but under a carport and I do have a nylon bike cover.

[wingnut]

Mine broke in the same place. Friend of mine used a wire wielder on it and its been good for over a year. Just stuff some rags in the ports for now

[oseaghdha]

Mine did that also. Seems like the left side usually breaks.
You only see right sides for sale.

[cokeman]

There is a reason why the left side goes, Its called a side stand. Water has to settle somewhere. I have a set in the garage that did the same thing. I had them welded and they look pretty good now. Haven't tried them though.

[thewiz]

Just did my SF two weeks ago ...

I had a nice clean, almost perfectly round break in the same damn spot. Planedick gas welded it but it didn't last too long. I then took it in to a shop where they arc welded it and put a big ole fat bead in there. So far so good ... I've been resisting an aftermarket pipe as hard as I can ... even to the point of spending more to retain an original exhaust ... not sure it was the best thing for me to do.

Your break looks pretty jagged and perhaps even pretty rusty .... maybe if there is some good metal somewhere in the area left to weld to; it could possibly be sleeved and welded.

Sadly though, it looks like you're due for a different system sometime soon anyway

[mason79]

mine is a cleaner break, the hose clamp the po placed on it holds, although it leaks, the sidestand, bangs on that side constantly causing the stress related failure, in my opinion.

[Ken Talbot]

Yup, big ole bead of stainless from a wire feed welder - that'll smarten it up. I think the guys at my local fabricating shop gauge the arrival of spring by when I show up with one or more pieces of Tsunami or Purple Reign for a bit of their magic.

[corey]

I'd go with something new. I've got some Jardines... me gusta mucho. Good sound, good response.

Rejetting your carbs will take a philips and a flat head screw driver, once you get the carbs off that is. Maybe also some needle nose pliers... minimal stuff in my opinion. I don't remember what all to get the air box off, since I haven't had mine on the bike in 4 years or so (cone pod filters).... and as far as what to rejet to there is a good calculator on this site. Its spot on.

...or weld and reweld and reweld... up to you!

[BigDick]

Thanks everyone, Corey that's more or less what i was planning to do. while I was fiddling with it i pulled my plugs for sh!ts and giggles, all of them are nice black and crusty, running rich, never gonna hire someone else to work on her. but yeah, planning on a good 4 into 1 and k&n pods. Do you have any trouble with changing your oil or filter with that 4 into 1 jardine? I've read of a couple other people having issues with 4 into 1s but I don't remember the brand they were running.

[XSPastor]

Thanks everyone, Corey that's more or less what i was planning to do. while I was fiddling with it i pulled my plugs for sh!ts and giggles, all of them are nice black and crusty, running rich, never gonna hire someone else to work on her. but yeah, planning on a good 4 into 1 and k&n pods. Do you have any trouble with changing your oil or filter with that 4 into 1 jardine? I've read of a couple other people having issues with 4 into 1s but I don't remember the brand they were running.

I've got the Jardine 4 to 1 and I've had no trouble changing the oil. Still have the center and side stand too.

[corey]

Should be fine on changing your oil/filter, as Pastor says.

I think the pods are a must.... just because they make carb work SO much easier. I hated the stock air box, both for functionality and looks. I don't think the pods improved my performance much... maybe shifted where the power hits a bit.

I think if you spent the money and time in exhaust and new intake filters you would really enjoy the money.

Remember to factor in intake mods for your rejet calculations.

[Grahamdownunder]

I am new to this board but the XS1100 holds a soft spot in my heart .
I bought a new XS1100 in Australia when they were first out ( after about 3 months )
The exhaust wa a know problem in fact after about 4 mths mine rusted out on the left side and by the time they had new exhaust in ( about a mounth ) for a warrenty claim the RH side had a hole in it .

Now when I got the bike home with the new exhaust I removed them and sprayed fish oil compound from the header and muffler section. This stopped them rusting out as many other had to replace them in about 1 years time . Poor electroplating is what I think was the problem . I would do this again as beside it smelling for a few weeks and some baked on residue on the back of the exhaust was fine.