Exhaust Leak Found

[ErnieA]

Much to my dismay our LT developed an exhaust leak on the WCR trip. I was hoping that it was something easy to fix, however the muffler is cracked and the extended warranty does not cover it. Thanks to an old friend of this site a replacement has been found and we'll be back on the road soon. I guess after 4 years and over 93k I can't be too upset with the old girl for giving up her pipe. ;)

[grifscoots]

Weld her up and have a spare.

[ErnieA]

Weld her up and have a spare.

I'm gunna do just that I think. I'm going to talk with a friend today who has a TIG Welder. Sounds like a good time hangin' at the welding shop with a cold one in hand.;)

[dshealey]

Much to my dismay our LT developed an exhaust leak on the WCR trip. I was hoping that it was something easy to fix, however the muffler is cracked and the extended warranty does not cover it. Thanks to an old friend of this site a replacement has been found and we'll be back on the road soon. I guess after 4 years and over 93k I can't be too upset with the old girl for giving up her pipe. ;)

Not uncommon. Several of us have welded these and kept going. I have access to a TIG welder here at work, and my re-weld was better than the stock weld.

[AlaskaFish]

Bummer Ernie! So what was your first indication that she was leaking? Was it making unusual noises? Or did you just spot it visually? Did it affect the performance of the Bike?

Tks in advance,
John

[amarider]

Hey Ernie,
That's right where mine cracked all the way around. Sort of sounded like a turbo deisel on crack. :p Had it TIG welded and it lasted a lot of miles until I sold her.
Mine was easy to find by all the black soot all around the left passenger foot peg.

[Dick]

Hey Ernie,
That's right where mine cracked all the way around. Sort of sounded like a turbo deisel on crack. :p Had it TIG welded and it lasted a lot of miles until I sold her.
Mine was easy to find by all the black soot all around the left passenger foot peg.
Ed Zachery how and where Dave Moore found his pipe cracked, John. Tried the muffler tape route just to git some mileage outta the thang, butt that didn't work at all. Ended up with a new one, I think.

BTW - I've got four of those exhaust systems at my storage unit. Two of 'em are cracked just like the pic above; another is one of ole Toad's that had the head flange insert loose (Hank found it when doing the clutch removal work, so he gave me one from one of the earlier Remus swapouts); and yet another (a good one) that I bought off of Denny Kintner when he wuz selling his LT and parts. I tried fitting Denny's to Toad, butt I think wherever Denny got it, it came off a wrecked bike, cuz it is tweaked just enough that it doesn't meet up with Toad's layout. (Denny wouldn't know that, as he never tried to install it on his LT).

Anyway, if someone wants some TIG practice, they're welcome to any of the four. Just pay for shipping (IIRC, it wuz ~50 bones to ship Denny's from WY to TX). None of 'em have the chrome dress/heat shield, and only Denny's has four good crush washer rings.

Pardon the slight thread hi-jack, Ernie. Good luck with your fix.

[ErnieA]

Not uncommon. Several of us have welded these and kept going. I have access to a TIG welder here at work, and my re-weld was better than the stock weld.

That is good to know. I'm pulling her off tonight and seeing what needs to be done. What a bummer I only got 93k out of her, huh? I'm not surprised that she is starting to show her age, however I want to do all I can to keep her runnin' and lookin' good. Thanks for the reply.

[ErnieA]

Bummer Ernie! So what was your first indication that she was leaking? Was it making unusual noises? Or did you just spot it visually? Did it affect the performance of the Bike?

Tks in advance,
John

Pauline and I noticed a "tinny" rattle sound coming from under the engine. I was thinking the headers were loosening up again. Then a low growl in 1st through 3rd under torque. I began to worry a little. Then there was a tell-tale sign of exhaust soot near the passenger footpeg.

I didn't notice any appreciable difference in preformance (one way or the other).

[ErnieA]

Anyway, if someone wants some TIG practice, they're welcome to any of the four. Just pay for shipping (IIRC, it wuz ~50 bones to ship Denny's from WY to TX). None of 'em have the chrome dress/heat shield, and only Denny's has four good crush washer rings.

Pardon the slight thread hi-jack, Ernie. Good luck with your fix.

Hi-jack away anytime Dick. Either way, with the replacement or this one repaired, I'll be able to help someone else sometime with a usable exhaust if they need one. I'm grateful for the help people on this site give,and I am always willing to do in kind. Thanks for the info. I might be looking for a couple more welding projects when I'm through.