Kawasaki ER6 Exhaust Snapped

teuma86 · Scooby Slapper Joined: 16 Sep 2008 Karma :

Went out riding today. Was going down the main road and noticed the engine a lot louder than usual.

Pulled over and noticed the sound was still loud, as if the exhaust has come off.

Rode the bike back home being careful and waited for everything to cool down and the pipe looks clean cut.

Can I just weld this back together?

How would this have happened?

Pics

It appears snapped all the way round at the welding point to the right of where my finger is in the first image.

https://onlyican.com/test_samples/biking/IMAG0106.jpg

https://onlyican.com/test_samples/biking/IMAG0108.jpg

https://onlyican.com/test_samples/biking/IMAG0105.jpg[/img]

..... · Quote Me Happy Joined: 15 Jan 2005 Karma :

Isn't the exhaust rotting a common problem on the ER6? Was it Sickpup who had the same problem?

Anyway, that looks like you could weld it up easily enough.

teuma86 · Scooby Slapper Joined: 16 Sep 2008 Karma :

I am hearing it is a common problem.

I was googling the problem when I found this post from a few years ago.

https://www.bikechatforums.com/viewtopic.php?p=2184305

From what I understand, Kawasaki should sort this for free.

I don't have much faith in my local Kawasaki Dealer. I recently got a service from them and I have had nothing but issues since. (I have even found Bolts on the bike a bit loose when My uncle and I have been working on it.)

So I will have to travel to another one. Or just ask someone I know to weld it.

..... · Quote Me Happy Joined: 15 Jan 2005 Karma :

It's not a Kawasaki dealer in Guildford by any chance?

teuma86 · Scooby Slapper Joined: 16 Sep 2008 Karma :

I wont mention names / location for fear of being accused of Slander but I have sent you a message.

..... · Quote Me Happy Joined: 15 Jan 2005 Karma :

TBF I wasn't guessing the location of the dealer due to bad service but more from your dot on the location map.

I rate these guys

https://www.normandymotorcycles.co.uk/

Always helpful and the one time they did some work to my bike they charged a very fair rate. It's also where I go for my MOTs.

andys675 · World Chat Champion Joined: 08 Feb 2007 Karma :

take it to a welders and get a piece of tube welded onto it, I used bob wallet in dudley if it helps?

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Amm I missing something? isn't that just where the cat/'endcan' joins to the downpipes? you can see the bolt from the clamo in the picture, loosen it off knock the can forward then tighten it again, it should be ok
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teuma86 · Scooby Slapper Joined: 16 Sep 2008 Karma :

Rogerborg · nimbA Joined: 26 Oct 2010 Karma :

Uh... what Chris said. There's a clamp clearly visible in the picture. Slacken, push system back together, tighten.

If it's still not gas tight, then slap some exhaust assembly paste in, or use 'metal repair tape' over the join - essentially sticky backed tin foil.
____________________
Biking is 1/20th as dangerous as horse riding.
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teuma86 · Scooby Slapper Joined: 16 Sep 2008 Karma :

I have phoned a Kawasaki Dealer. As if they want to repair it properly for free, i would prefer that.

But thanks for the other options. I will look into them if Kawasaki say no.

Originally the guy wanted me to ride the bike down to them with the warranty book. so they can then look at it and then contact Kawasaki and wait for a response.

But I managed to get them to look at some pictures I emailed them and I will drive the book down.

I dont fancy riding to the shop and back unless I have to with the exhaust.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

To me that looks like a clamp has come loose. Laughing

____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

P.addy · Red Rocket Joined: 14 Feb 2008 Karma :

OP, just incase you missed it... 2 minute job.

teuma86 · Scooby Slapper Joined: 16 Sep 2008 Karma :

Saw it. I will have a look tonight.

My only question is that IF this is that simple of a fix. How come it was not mentioned here
https://www.bikechatforums.com/viewtopic.php?p=2184305

It would explain the how it happens tho.

Wear and vibration feeds the pipe out over time.

P.addy · Red Rocket Joined: 14 Feb 2008 Karma :

Not mentioned probably because the people with newer bikes fancy going to the dealers to get bum fucked.

MarkJ · World Chat Champion Joined: 11 Apr 2006 Karma :

That doesn't look like you can just push it on to me. Looks like the weld between the wider and narrower part of the exhaust that slips over the rear part has split.

teuma86 · Scooby Slapper Joined: 16 Sep 2008 Karma :

MarkJ · World Chat Champion Joined: 11 Apr 2006 Karma :

I might be wrong actually. Parts diagram for 2006 ER6n:
https://www.kawasakimotorcyclespares.co.uk/spares/epcImages/11378/20940.jpg

Anyone figure out what part of the exhaust goes over the other?

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

The clamp goes over the end of the can which goes over the downpips.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

teuma86 · Scooby Slapper Joined: 16 Sep 2008 Karma :

Silly question, I think I should look at the bike before asking this but here it goes.

If the pipes are all connected and metal does not stretch and the silencer is attached via a bracket, how can I pull the pipe back into the clamp?

MarkJ · World Chat Champion Joined: 11 Apr 2006 Karma :

Looks like there may be a broken weld to me, parts diagram seems to show the weld that looks broken.

https://i53.tinypic.com/20b1wfn.jpg

https://i54.tinypic.com/2ro3v9x.jpg

Rogerborg · nimbA Joined: 26 Oct 2010 Karma :

Hard to tell from one picture. It could be that the clamp bolt has sheared, it could be that the noise is coming from somewhere not shown on that image.

10 minutes of investigation could save you a trip and the hassle of negotiating with a dealer, is all that we're suggesting.
____________________
Biking is 1/20th as dangerous as horse riding.
GONE: HN125-8, LF-250B, GPz 305, GPZ 500S, Burgman 400 // RIDING: F650GS (800 twin), Royal Enfield Bullet Electra 500 AVL, Ninja 250R because racebike

sebastianw · Spanner Monkey Joined: 22 May 2009 Karma :

It's a well known ER6 problem, the pipe is cracked and you need replacement pi[pes (under warranty usually) or get it welded.

There's a lot of information here if you do a search

https://www.bikersoracle.com/er5/forum/forumdisplay.php?f=28

teuma86 · Scooby Slapper Joined: 16 Sep 2008 Karma :

I popped home at lunch and had a quick look. Granted it was very quick.

Correct me if I am wrong in naming, I am trying to learn

The down Pipe (The one on the right) Does not move into the Bracket.
The only logical way I can see to get the Downpipe connected to the silencer via the bracket is to move the bracket across, as the silencer is attached with its own bracket.

Under this theory, unless the bracket joining the 2 has moved (it didn't feel loose when I looked) then by moving the bracket to the downpipe, it would then leave a gap on the silencer.

HD · World Chat Champion Joined: 16 Dec 2009 Karma :

Just disconnect the silencer from the bike, try to slide it back down the downpipe. If it goes then tighten the clamp and remount the silencer.

If it doesn't move, then it is likely it may need a welding Thumbs Up

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