exaust cracked

[speedlimit85]

Maybe I take too many bumpy back roads. It's not too rusty, but today I heard rattling and there is a big crack through the right side just in front of the cross over.

Can this be repaired, welded, JB? Could be hard to replace. I rode aroundy with it like that today, It's not dangerous yet right?

[speedlimit85]

[speedlimit85]

Trying jb weld exhaust...

[DiverRay]

They rust from the inside, so you are probably close to "end of life" on the factory system. The JB may give you another year or two, so it's a good first try. If you know how to weld, or have a GOOD local welder, that could give you about four more years.

[motoman]

Speedlimit,, tack weld in four locations with a wire-feed welderl while exhaust is in place. Remove right side exhaust and finish welding break preferably using a torch and welding rod. Torch welding this spreads the heat across pipe while welding. Grind it smooth with an angle head grinder using a flap sanding disc. Paint the area using a can of Dupli-Colors High Temp Silver. That fix will last rest of bikes life. Just a tried and true procedure from a certified welder/fabricator.

[motoman]

BTW, Dupli-Color brand spray paints are primarily located at your local NAPA dealers. It is also a high quality paint brand that stays looking good for many years!

[2WheelFun]

I agree. Go right to a good weld shop. Do not use any epoxy as it will contaminate any weld repair.

[cajun31]

I had this happen on my original to me MNS. I took the bike to a reputable welder so that he could spot weld it to hold it together. I then took the exhaust off the bike and brought it back to him to finish the job. It would be best if you can find someone that can do TIG.

[speedlimit85]

better

[2WheelFun]

Hit it with a brush to clean off the oxidation and put a bit of high temp paint on it to keep it from rusting out in the heat affected zones of the weld.

[speedlimit85]

now the left side crack is all the way through...How hard is it to remove for weld to go all the way around? would I need new exhaust gaskets?

[DiverRay]

I had to do my special exhaust this past spring. Right side cracked all around. Lucky for me I have a TIG welder and was able to weld it up. I did add some extra steel to help support the pipe at the break. The hard part is trying to get a clean weld, between the carbon, nickel plating, and thin "good" steel to weld on. I know it's not pretty, but it should hold for another 30 years with any luck. My next task is going to build a complete exhaust system for the 1978 I'm working on. That is going to be a 4 into 1 made of stainless steel.

[bikerphil]

Many times the exhaust header gaskets can be re-used, but not always. Probably a good idea to change them while it's off. The new gaskets can be held into the head while assembling with a few dabs of grease.

Yes, the factory exhaust is a bit of a pain to remove/install, mostly because of the weight of it.

https://www.amazon.com/CALTRIC-Exhaust-Muffler-Gaskets-1978-1981/dp/B01N51W95R/ref=sr_1_1_sspa?crid=2LFYQSMF90XB4&dib=eyJ2IjoiMSJ 9.TEGBA1aaM_DG-ilEGoKJR0Li7O1dSE7f6kSa1mg0cYd7w6kOC3EOOQifOLaq6lJ YlIbP07zE1p6QsFc3ZKFw-AvSBZoiVqDdjALNYHDnIV81alZqpaiXtz2tmHxgtdjTuLJi-7PbrxvHq4q2ty8rWNnyyZFqMrJlDLb6OMwfPt1suCoGZJxeWw3 Hx-HeOUGAjNNCIys__ITvBZHGSSDps9lmuPN6tIEWDGA0EclQ1gUS hywTmJK4fcUAlqfAmUTnSbMxHAueAgTPZVZ4cD88yU8PEd1F9U rKOScO-HES4hI.gYF1YyEtdhgvFOGgm7IXrFjQXQ8UHufdVwpuXz5QtZw &dib_tag=se&keywords=xs1100+exhaust+gaskets&qid =17 84652299&sprefix=xs1100+exhaust+gaskets%2Caps%2C29 4&sr=8-1-spons&sp_csd=d2lkZ2V0TmFtZT1zcF9hdGY&psc=1

[speedlimit85]

He's gonna weld it on the bike. I just stopped at the shop. He welded the other side with good results. I thanked him for changing tires and brakes in time to ride back from the everglades in 7 hours. His eyes popped out of his head "on that thing?"

[bikerphil]

Yep, people sure underestimate what these bikes are capable of. That's good news that the exhaust can be welded right there on the bike.