Broken Header NEEDS ADVICE!!!

[Dnali]

ok so here is my delema. bought two yamaha 200e's. awsome machines, lots of power. fun to ride. but one of them has broken a header. i have yet to take it apart yet as there up north rite now. but ive been brain storming. oem factory this part is like $300. Cant find any used parts anywhere. so my plan is this.

the break (marked in pink). is just behind the bracket (wich i have marked 7). what i want to do is either

A. take the broken peice out of the engine. then weld a sleve(marked in blue) dirctly to the number seven bracket then to my header pipe.

or B. leave the broken peice inside and just weld my sleve over top.

i do not know if this will efeect the way my engine fires if i take this ring out if it will ruin the engine. also if i leave it in if there is a way for broken peices and debris to get into the engine.

i just got these mackines a month ago and have only been out a couple weekends. but im sold so far.

Any advice will help me alot.

c posted picture for diagram.

[Dnali]

bump: bump:

[Dirtcrasher]

I'd say do the outside sleeve and braise it or mig weld it....

I think allot of the inner rings are there for manufacturing purposes. BUT, the gasket would still have to cover all the area if you know what I mean......

[Dnali]

I'd say do the outside sleeve and braise it or mig weld it....

I think allot of the inner rings are there for manufacturing purposes. BUT, the gasket would still have to cover all the area if you know what I mean......


yea i figured leaving the gasket in would be my best bet.im only puting a sleve because where the weld broke its deteriorating a bit. do i need to go back a few inches for a nice spot to weld.

thanks alot. ordered some aftermarket motorcycle mufflers and some new tires for my machine.

both trikes are 84 200e shafts.

i dream every night of riding these bikes. Only get to ride on weekends.

thanks again.

D

[Dirtcrasher]

IDK how much welding you've done......

But, yes, get back to some solid material. And what are you welding with?

Exhausts are very thin..... You need a good Mig with adjustable heat and wire speed or I really like oxy/acetylene for thin stuff with a flux coated braising rod. It's very strong, won't burn thru and easy to use if you have some experience.

Can you post a good picture of the damaged area??

[SWIGIN]

i have built and shortend many pipes in my day....what i would do is take the mounting flange off the head and grind it smooth so you have a good clean place to weld.

then i would cut it back an inch or whatever you need and clean that as well. then just weld it back on.

here is a pic of one of the last headers i shortend up....see how it hugs the jug, i took like 2'' out of it. as far as your silencer mount, a simple flat steel bar will work.

[Dnali]

IDK how much welding you've done......

But, yes, get back to some solid material. And what are you welding with?

Exhausts are very thin..... You need a good Mig with adjustable heat and wire speed or I really like oxy/acetylene for thin stuff with a flux coated braising rod. It's very strong, won't burn thru and easy to use if you have some experience.

Can you post a good picture of the damaged area??

ive got an arc welder from canadian tire. just a cheepy. it has two heat settings not sure. im not that experienced with welding. this will be my first project that i weld that will have any sugnificance. umm judging from what SWIGIN wrote this looks like an easy fix however i dont want to mangle my header to the point of no return.

i know a guy who runs a bike shop who could weld it up but im just lookin for the cheepest way out.

and if a mig welder wont work then im thinkin thats my next bext option.

D.

[Dnali]

oh and sorry i dont have a good photo of the dammaged area. bike is up north. should have one by the weekend.

[81k]

not sure if you're interested, but DG sells an aftermarket exhaust for these trikes, and I believe it is a complete system, from head to muffler. I believe they sell for about $160 in the Dennis Kirk catalog.

[Dnali]

not sure if you're interested, but DG sells an aftermarket exhaust for these trikes, and I believe it is a complete system, from head to muffler.

do they have a web site???

[Howdy]

The might be a couple good used head pipes at the shop. If your interested send me a PM and I will check Friday.
Howdy

[oscarmayer]

welding time. Tig that puppy!

[Dnali]

welding time. Tig that puppy!

well i have this crappy canadian tire arc stick welder. here are the specs. if i cant use this i will most likely take it in to my mechanic and have him seal it up.

Features

Power: 120V
Output current: 50 - 70 A
Metal thickness: 18-gauge to 1/8"
Duty-cycle: 10% at 70 A; 20% at 50 A
Electrodes used: 1/16, 5/64"
Two heat settings with 1/16¿ or 5/64¿ welding rods
Thermal overload protection
Easy-start ensures smoother arc
Includes electrode, welding shield, hammer/brush, welding rods and cord storage attachments
Three-year manufacturer's repair warranty

[oscarmayer]

NO, take it to a muffler shop. a big shop can weld it even with a mig if they have a good welding guy and a decent welder.

[Dnali]

NO, take it to a muffler shop. a big shop can weld it even with a mig if they have a good welding guy and a decent welder.

awsome. realy you all answwered what i was out to know. thanks alot guys youve been a great help. i am going to take the bike in to my local bike mechanic and have them seal it up. as i am quite an inexperienced welder and i dont want to mess any thing up.

thanks again for all your guys support.

happy riding out there. Dave

[Howdy]

If you need a complete exhaust I have one. The head pipe is on it pretty good ( never took one apart ).
Thanks
Howdy

[Howdy]

I did find just a header pipe as well, so you have backup if needed.
Howdy

[Dnali]

I did find just a header pipe as well, so you have backup if needed.
Howdy

yes i would definatly be interested in both of those. how much would u supose shipping would be on them. let me know i am highly interested for sure

Thanks

D

[Howdy]

yes i would definatly be interested in both of those. how much would u supose shipping would be on them. let me know i am highly interested for sure

Thanks

D

I'm estimating the shipping weight to be 11-14 lbs for the complete exhaust and the extra head pipe. www.usps.com show the shipping would run aprox $36.50 - $41.75. I will have to double check the price at the post office to see if there are any cheaper options.
Howdy