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Dan Diego

Broken/lost header pipe (KTM 990 Adventure)

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I was out riding with another SDAR guy this weekend and felt something give way shortly after leaving home. When I rode up to the meeting spot, we could tell the bike was super loud (well...louder than usual). I thought I'd lost a header bolt or the exhaust was loose somewhere. But a closer inspection revealed that an entire piece was missing. Just gone. (It was the elbow between the header and exhaust like the below photo.)

A little research showed that this is fairly common, unfortunately. 

http://advrider.com/index.php?threads/ehh-lost-half-an-exhaust-header.881020/

Instead of welding/repairing it, I may just buy a used set and replace the entire thing. 

Has anyone experienced this? Ideas on how it happens? There was no indication it was broken before it went bye-bye.

 

IMG_3796.JPG

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Expansion and contraction with high heat over time will fatigue the metal. Add in a rigid mounting, plus over-all vibration = header crack.  Bendy part probably is under stress at times.  Intersting that a big chunk fell out.

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If the lambda sensors aren't damaged, I can have a local muffler shop weld in a replacement part (about a 10" piece of header). That'll keep me from having to replace most or all of it.  If that's not possible, I'll buy and swap in a used set.

Just peculiar that it occurs often enough, especially in the big KTMs.  I've seen corrosion in other bike systems, but usually there's a warning.

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You Must be Kidding!  Calling KTM NA.. You gotta fix this or I'm posting on, You know ADV Middle Aged Touring Inc.

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Ha ha! They'll get right on it, I'm sure. 

If none of you KTM know-it-all's have a better idea, I'm having a muffler shop weld in the  elbow. 

Or I can cruise over to The Kug's place at midnight and let his neighbors diagnose the issue...

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Used or muffler shop most might not carry pipe that small though in stock. Bring bike with you so they can make sure it lines up

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To prevent this i hadmine ceramic coatedinside and out

ive lostthe sensor plugbut this is new to me material is pretty thin to begin with i assume this is the frontheaderpipe?

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4 hours ago, Dan Diego said:

Ha ha! They'll get right on it, I'm sure. 

If none of you KTM know-it-all's have a better idea, I'm having a muffler shop weld in the  elbow. 

Or I can cruise over to The Kug's place at midnight and let his neighbors diagnose the issue...

If it is a saturday they will be still up !

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9 hours ago, DSM8 said:

To prevent this i hadmine ceramic coatedinside and out

ive lostthe sensor plugbut this is new to me material is pretty thin to begin with i assume this is the frontheaderpipe?

I read the same thing about the ceramic addition on ADV. It's the curved elbow right by the footpegs. PMing you.

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