Cracked exhaust header. - - Excellence in Motion
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post #1 of 4 (permalink) Old Sep 5th, 2016, 5:26 pm Thread Starter
Join Date: Aug 2013
Location: Riverton, WY, USA
Posts: 23
Cracked exhaust header.

Anyone experienced a cracked exhaust header? The dealer pointed a crack in mine out to me while I was having a service done. They say it's a common failure point. I'm gonna try a welder I know that is pretty talented. I can't see paying north of 2 K to replace it with a known flawed part.
Any suggestions?
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post #2 of 4 (permalink) Old Sep 5th, 2016, 5:54 pm
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The exhaust header and the bolt/bush on the muffler are a restraint for the engine. The mounts take the weight but the header stiffens the fore and aft movement. The big problem I had on my '97 was the flanges on each header pipe were very badly corroded. They make the one piece system from stainless but the flanges are mild steel and you can't replace them without sawing up the pipes. I had to buy a nearly new take off - huge monster one piece, but very quiet and stealthy!

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post #3 of 4 (permalink) Old Sep 6th, 2016, 9:19 pm
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I had a K1100RS that cracked the exhaust where the 4 pipes come together. I welded it back together using an oxygen acetelyne torch and 56% silver brazing alloy. Was still 100% repaired 3 years later when I bought my K12

Mike Kelly

Triple M Engineering


Stanley, NC
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post #4 of 4 (permalink) Old Sep 7th, 2016, 7:59 am
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Location: Newcastle, NSW, Australia
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Yeah. find someone with a Tig welder, or someone good with the Oxy torch, a Mig or Stick isn't really what you want for this.

2002 K1200RS -- more than 100,000Kms on the clock, just ran in.
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