Another Suzuki Bandit Exhaust Problem

[Bandit600s]

Morning All,

Now not being very mechanically minded I thought I would come seek some adivce from you all.

My bandit 2003 600s 23,000 went in for some tyres and service only to be told that the join between the silencer and downpipes has a crack 2/3rds round due to rust and that it is an MOT failure. Apparently a common problem on Bandits due to mild steel. (Been trying to research)
My mechanic said that I will need new downpipes and worse case if the rust has done more damage a whole new exhaust system. He is trying to find some prices and thinks he can get new downpipes etc for maybe £200., and said a factory one would set me back £600 odd. Is this a good price? Got any places you've used in the past I could try?

As for removing the pipes apparently he will need to get a guy to heat the allen bolts so they don't snap otherwise a whole different problem of drilling them out etc.

Any thoughts or ways I could save a bit of money always welcome as I need to get it sorted before my bikesafe rideout.

Thanks

[cb1rocket]

I would look at the downpipes first for the crack and see if the exhaust gases are actually leaking - just to make sure he's not fobbing you off.

thats news to me, last I hear they were stainless steel as standard?!

Motad is a supplier of aftermarket exhaust system and also Predator Exhausts.

[Bandit600s]

[quote="cb1rocket"]I would look at the downpipes first for the crack and see if the exhaust gases are actually leaking - just to make sure he's not fobbing you off.

thats news to me, last I hear they were stainless steel as standard?!

Motad is a supplier of aftermarket exhaust system and also Predator Exhausts.[/quote]

Appartently the bit between the can and the downpipes is mild steel the rest is stainless steel (can/downpipes etc)...

[chris-red]

If it is at the collector box, Bandit mania weld them up for about £80

https://www.banditmania.co.uk/exhaust_systems_&_cans.htm

See half way down the page.
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[0l0dom0l0]

Well, 23,000 miles is pretty good for a standard Bandit collector! It doesn't sound unreasonable its gone after that many miles. Yes it probably is an MOT failure as the exhaust is effectively leaking.

Don't let him talk shit. These are what you want. (They are IDENTICAL to the Suzuki ones, not like the cheap shitty Chinese versions which loose all your midrange).

https://cgi.ebay.co.uk/GSF600-Bandit-600-Suzuki-downpipes-stainless-steel_W0QQitemZ350439791075QQihZ022QQcategoryZ10534QQssPageNameZWDVWQQrdZ1QQcmdZViewItem#ht_500wt_1156

Don't pay any more than that for any exhaust. This is the best you will get for your money I guarantee you.

He will probably have to heat the nuts, but if the studs don't come out, then they are perfectly fine to leave. It depends how bad they are. Where are you located? I will happily do it for you if your local as I have just done the exhaust on my Fazer.

I wouldn't pay more than £40 to have that fitted at a garage if you give him all the parts listed below except the copper grease) Probably take us 40 mins or so from run to run.

List of parts you will need:

New pipes
New Gaskets
Penetrating Oil
New nuts (preferably brass)
Copper Grease

Job done

Hope that helps.
____________________
CBT Passed: 30/08/2009, Theory Passed: 31/08/2010, Mod 1 Passed: 6/9/2010, Mod 2 Passed: 13/09/2010. Restriction ended 13/09/2012.

Bikes: 2007 Derbi GPR 50, 1998 Yamaha Fazer 600 (written off), 2002 Yamaha Fazer 600, 1994 CBR 600F, 2003 Triumph Daytona 600, Kawasaki ZX6R J1.....Current: 2006 Yamaha FZ6, 1998 Suzuki TL1000R and a Honda VFR 400 NC30.

[Bandit600s]

Thanks all for your adivce. It gets interesting but probably more expensive.

It is indeed the collector box that has rusted through, the guy can get me new downpipes for £169.99 plus postage etc or after reading your posts welding is now an option and will be it for around £100 mark. Unfortunaltley he sheered one of my bolts getting the pipes off so another engineer will need to get them off (joy).

Think I will go with the welding option as the downpipes themselves are fine and the can as well.

I had planned to replace both tyres on the bike but now with costs mounting up I might just have to replace the front (BT021s)....

[0l0dom0l0]

Just make sure your not getting screwed.

I assume he's covering the costs of the other guy getting them out seeing as it was his fault that it sheered off?
____________________
CBT Passed: 30/08/2009, Theory Passed: 31/08/2010, Mod 1 Passed: 6/9/2010, Mod 2 Passed: 13/09/2010. Restriction ended 13/09/2012.

Bikes: 2007 Derbi GPR 50, 1998 Yamaha Fazer 600 (written off), 2002 Yamaha Fazer 600, 1994 CBR 600F, 2003 Triumph Daytona 600, Kawasaki ZX6R J1.....Current: 2006 Yamaha FZ6, 1998 Suzuki TL1000R and a Honda VFR 400 NC30.

[Scotsman37]

https://www.peugeotscooterspares.co.uk/spares/epcImages/5832/15.jpg

https://www.peugeotscooterspares.co.uk/spares/epc2.asp?ModelID=5841&pageID=T6364

Ebay

https://cgi.ebay.co.uk/GSF600-GSF-600-BANDIT-EXHAUST-FRONTPIPES-DOWNPIPES-/130488415347?pt=UK_Motorcycle_Parts&hash=item1e61b73473

https://cgi.ebay.co.uk/Suzuki-GSF600-GSF-600-Bandit-01-Exhaust-Front-Pipes-/400127645085?pt=UK_Motorcycle_Parts&hash=item5d2977559d

[Bandit600s]

Wow nearly £800 for a new Suzuki part... wonder whether that still has a crappy collector box.

The mechanic is likely to charge me for his effort of sheering off a bolt, will argue it but he will use the classic line of 'well I did explain that this could happen' !!

Think I should take a basic mechanics course in the winter might help me save £'s on this kind of work.

Keep the advice coming

[Bezzer]

I bought a small piece (150mm) of 2 1/2"/63mm stainless exhaust pipe from fleabay for under a tenner, cut it to length then took it to a local stainless welder who charged me a tenner to weld it in, job done.
That's the cheapest way - the pipe is 63mm OD and 60mm ID (which is the critical measurement as that's the OE size to fit the gasket.) needs to be 65mm long and it sits then on the crossmember inside the collector and sticks out the same as OE, use an angle grinder or hacksaw to cut 4 or 5 1" long slots so you can clamp it up to the link pipe afterwards. Cut out the rotten mild steel piece and clean it up before you take it in and just take note of how the pipe sticks out at an angle from the collector so you can set it up for the welder, easy enough as it does follow the lines of the collector.
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I used to be indecisive but now I'm not quite so sure.

[cb1rocket]

as dom has said this:

https://cgi.ebay.co.uk/GSF600-Bandit-600-Suzuki-downpipes-stainless-steel_W0QQitemZ350439791075QQihZ022QQcategoryZ10534QQssPageNameZWDVWQQrdZ1QQcmdZViewItem#ht_500wt_1156

sounds the best bit to buy, the weld up jobby is likely to fail again and rust like buggery considering how much your going to be charged.

Its common for the garage to charge for work where removal is difficult due to crap/crud and general seizing problems as oppose to a bike thats been kept well with all bolts greased etc.

Don't want to offend, just saying but I can see where there coming from. Hence why I do all my own servicing.

My brake caliper pins were shot when they were due for a pad change, was cheaper to just replace the calipers rather than pay someone to fiddle which I found out to myself after spending 3 evenings getting the bugger out!

[Bezzer]

[0l0dom0l0]

Again, where are you based?

There is a welder about 30 seconds from my house and I like Bezzers idea the most.

I also know a guy who will probably be able to get your studs out.
____________________
CBT Passed: 30/08/2009, Theory Passed: 31/08/2010, Mod 1 Passed: 6/9/2010, Mod 2 Passed: 13/09/2010. Restriction ended 13/09/2012.

Bikes: 2007 Derbi GPR 50, 1998 Yamaha Fazer 600 (written off), 2002 Yamaha Fazer 600, 1994 CBR 600F, 2003 Triumph Daytona 600, Kawasaki ZX6R J1.....Current: 2006 Yamaha FZ6, 1998 Suzuki TL1000R and a Honda VFR 400 NC30.

[cb1rocket]

[cb1rocket]

I have a group of welders next door to me in my office.......hehe

[Bandit600s]

Am based by the Essex/Cambridgeshire border.

[0l0dom0l0]

Oo bit far from me then
____________________
CBT Passed: 30/08/2009, Theory Passed: 31/08/2010, Mod 1 Passed: 6/9/2010, Mod 2 Passed: 13/09/2010. Restriction ended 13/09/2012.

Bikes: 2007 Derbi GPR 50, 1998 Yamaha Fazer 600 (written off), 2002 Yamaha Fazer 600, 1994 CBR 600F, 2003 Triumph Daytona 600, Kawasaki ZX6R J1.....Current: 2006 Yamaha FZ6, 1998 Suzuki TL1000R and a Honda VFR 400 NC30.

[Scotsman37]

[dragstaar]

this happened to my bandit600 and indeed, it was farting out gas leaks, so it failed MOT.

It wasn't so much the collector as such for mine, but the clamp had rotted, so there was nowhere to actually put the gasket!

I got this:

https://cgi.ebay.co.uk/Exhaust-Collector-Box-Gasket-Seal-Suzuki-Bandit-/400167512570?pt=UK_Motorcycle_Parts&hash=item5d2bd7a9fa

Its a wire mesh gasket, which is flexible, so i shoved it in what remained of the collector box, then squeezed the exhaust pipe into it. Passed the MOT with flying colours, and I thought it was a bodge, bu it really has lasted me a long time. 10,000 miles in fact!! and its passed 2 MOTs like that.

I'm still on the lookout for a cheapo set of downpipes though. But this is defo worth looking into

[Paxovasa]

The collector box on bandits is made out of soft steel and is a well known fault. Mine went at 15,000, so I decided to get a whole new stainless steel exhaust system.

I got my new exhaust system through Kawasaki Newcastle and got them to fit it. Total price was £400 (I think it is a motard system). , although that was 3 years ago.

As has been suggested you can get a repair done to it.
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Suzuki GSF600 K3 (in the fastest colour, black).

[Bandit600s]

Just wanted to thank you all for your helpful advice, comments, links. I'm going to visit the mechanic tomorrow to check out the exhaust and sort out getting a repair done (I'll expect a guarantee on the welding carried out).

Once it is all done I'll update you with how it went and the cost!

Cheers

[Bezzer]