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Self-repair of a burnt motorcycle exhaust pipe

Since a lot of different adventures take place in the life of a real motorcyclist, it is not surprising that some of them are associated with the repair of a war horse. At some, I can’t say that it’s a great moment, you notice that the exhaust pipe has changed its color, somewhere there is exhaust fumes, and sometimes even condensation leaks. And oh, horror, your favorite velvety rumble sound turns into a hoarse asthmatic cough.

As the popular wisdom says: where it is thin, there it breaks. By the same logic, the exhaust pipe burns out. Basically, the collector suffers, it is also the knee. When hot gases leave the cylinders hastily, they inevitably act on the pipes. They try to make the collector as rounded as possible so as not to obstruct the flow of hot gases, which are most harmful precisely on the bends.

A clogged exhaust pipe will also speed up the burn-out process, as the gases will seek a way out under greater than usual pressure. This means that microcracks and traces of corrosion from condensate will grow faster.

Condensation is the second cause of exhaust system malfunction. It accumulates inside after stopping the engine as the system cools down.

Materials and methods for repair

The toolkit is quite simple, the question is in the price of the issue, the level of training and ease of use. The most common materials:

  • Corrugation is the easiest method for initial repairs. It is a flexible but heat-resistant pipe section with a metal lattice frame. It is used to cover the burned-out area, which allows solving problems with minor local problems.
  • Welding. If you are a master from God, or at least just have straight arms from the shoulder girdle, and not from the hip bone, then the repair is quickly and reliably carried out using welding. When it is not possible to do hot welding or there is not enough experience for beautiful and even seams, then cold welding will help out here. It does not require great knowledge and skills of an engineering genius, enough logic and all the same skillful hands.

  • Thermal tape and thermal sealants. A sufficiently large area is usually wrapped with tape, fixing both the burnout site itself and the neighboring areas for prevention and better reliability. It is more practical to treat joints and seams with sealants.

Stages of work

As with cleaning the exhaust system (“Self Cleaning Motorcycle Exhaust System”), local repairs will require a place to work. Once you have found a work space, you need to start dismantling. Carefully remove the damaged part of the exhaust system. By the way, ideally it should be completely disassembled in order to also clean it. It will not be superfluous, if you still work with it, why not clean it up?

And you will have to clean it in any case. Because it makes no sense to do repair work on a corroded or burnt-out area without cleaning the workplace. By the way, if you are a lover of chemical experiments, then treatment with anti-corrosion compounds will have to be done at the right time. The second stage will be the preparation of the local area, namely the removal of all damaged parts. To do this, you will need a brush and sandpaper. Do we remember the rule of interrupting risks? Your task is not to scratch the area into blood, dust and dust, but to remove plaque and prepare a plane for good adhesion of surfaces.

After carrying out the main repair part, welding or wrapping with thermal tape, the materials need time to solidify, take shape and all kinds of diffusion processes. Ideally, leave the element to dry for a day. So that later without consequences it could be put back.

Let me remind you that all these methods are temporary solutions. They will give you time to select and buy a new exhaust system part, but they won’t fix the problem permanently.

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