Exhaust Help (GPZ 500)

[JackDG]

Hi guys, as seen in photo there are 2 sizable holes where the 2 pipes merge into 1.

I have no experience welding / exhaust repairs but have friends who can help out.

From the photo is there any salvaging this? the metal around the holes is pretty flimsy and any putty just gets blown off.

thanks!

https://i.imgur.com/u4yazGb.jpg%20
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1992 GPZ 500

[colink98]

don't try to weld over the holes where its all thin and wasted away.
instead get matey to stick a nice triangle over the area and weld to a better part of the metal.

i even did the designs for you in paintUP.

https://i.imgur.com/W2lHklO.jpg
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PCX125 (stolen) - CBF600 (current)
Ride it like you stole it.
ride sensible and not like an idiot and you wont get 6 points in one week.

[pompousporcup...]

what that guy said ^^

They all go at the collector point there you could weld a plate in and it might help for a little while.

Is it the stock exhaust manifold?
edit: probably not as its 2-1

[JackDG]

Yeah triangle idea looks good, but there is a dip between the two pipes, so might be tricky to get a good seal :/


Unsure if they are stock - I know stock is a 2-2 config but am unsure if these are modified stock parts or some aftermarket / diff bike exhaust.
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1992 GPZ 500

[TheManWithThe...]

you could try an exhaust bandage or alternatively foil tape.

I've used the bandage on my ER5 when it went in exactly the same place, and the foil has worked higher up on the downpipes.

Slab a load of putty on, then stick the foil over it, then a bit of steel wool to bulk the area up, then wrap the fuck out of it with the bandage. With the foil tape i just filled the hole in with some putty, then taped over. Only trouble is getting the tape to stick properly, because the area will be very dirty so may not create a seal.
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MBK Nitro 50, Sold. Kawasaki ER-5, Honda ST1100
"Anyone can jump a motorcycle! The trouble begins when you try to land it..."

[Rogerborg]

I'm guessing that's an ER5 exhaust. The stock 2-into-2 GPZ500 system goes at the link pipe between the down pipes.

You can bodge it for a while as above. I'd go with plumbers silicon, then a fillet of steel or aluminium over that, then optionally bandage and/or foil tape, then wrap it in something to hold it on. Steel garden wire tightly wound around is my favourite.

But start saving up for a replacement, because once exhausts go, they tend to keep going.
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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

[stinkwheel]

Just a potential confounding factor.

What make is it?

It might be "stainless" (quotes intentional) which complicates welding.

Despite what the manufacturer insisted on here, the collets on the nexxus system I had on my GPZs were clearly either very inferior inox or simply mild steel and rotted off. Other parts may be similar.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Pete.]

[TheManWithThe...]

[ThatDippyTwat]

Anyone that can actually weld* will have a plate over that in half an hour, all prep and cutting included.

*real welding, not your mate from the pub with the £50 Clarke stick unit, that thinks a line of bird shit is actually a weld.

[Shinigami]

i've just plugged the holes in my gpz500 zorst with gungum for now

don't expect the bike to be around for that many years so i'm fine with bodges through MOT new zorst will be expensive (even if I can the the studs out....)
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Current: Honda City Fly CLR125 2003 Honda CB600F Hornet 2008 Yamaha FZ6 S2 + 1991 Kawasaki GPZ500
"Once you realize what a joke everything is, being the Comedian is the only thing that makes sense.

[Rogerborg]