Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Honda Tech
xr650l "creative" exaust mod. xr650l "creative" exaust mod.
Register FAQ Calendar Today's Posts
Honda Tech Honda Tech Forum - For Questions specific and of interest to Honda riders only.
Photo by Hendi Kaf, in Cambodia

I haven't been everywhere...
but it's on my list!


Photo by Hendi Kaf,
in Cambodia



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 22 Nov 2004
Registered Users
New on the HUBB
  
Join Date: Nov 2004
Location: Fairbanks, Alaska, Alaska
Posts: 3
xr650l "creative" exaust mod.
i have a 2003 xr650l with a broken exaust pipe running to the stock can (the rear half?). have a suppertrapp to add on. is there a "creative" way to deal with this or do i have to start shelling out some of my hard earned "fun tickets" and ordering parts.
Reply With Quote
  #2  
Old 22 Nov 2004
Steve Pickford's Avatar
Contributing Member
Veteran HUBBer
  
Join Date: Jul 2003
Location: Oxford, UK
Posts: 994
I wouldn't recommend trying to be creative without the use of a welder. MIG is the easiest.

Measure the OD of the broken pipe & try to find a match & make it fit. Bends can be made without a tube bender by cutting & shutting - patience is required though.
__________________
My photos: www.possu.smugmug.com
Reply With Quote
  #3  
Old 23 Nov 2004
LordStig's Avatar
Registered Users
HUBB regular
  
Join Date: Oct 2003
Location: Fife, Scotland
Posts: 96
A good source of tube of various diameters are the car exhaust centres - the skips outside these regularly have all kinds of pipe, and often have sections cut from new systems too.

It's often possible to make a new section by grinding (or hacksawing)slots in the ends of the tube, and fixing the new tube section in place using either proper bike exhaust clamps (neater) or car ones (stronger and better compression, but very ugly and sometimes with clearance problems)and some gun-gum or exhaust bandage. Sounds (and is) a bodge, but it works and lasts!

Pipe really needs a proper bender if you have to add a curve, but you might just be able to get away with filling the tube with sand and putting gentle curves that way. You really need an outer and inner guide spring to prevent the pipe collapsing, though (and a lot of strength!).

Stig
__________________
Tall men see everyone else's bald patch but their own.......
Reply With Quote
  #4  
Old 23 Nov 2004
Steve Pickford's Avatar
Contributing Member
Veteran HUBBer
  
Join Date: Jul 2003
Location: Oxford, UK
Posts: 994
I once fabricated a centre section of exhaust pipe for an XL500. Needed two bends, both about 120 degrees.

I cut four V-slots, about 2/3 pipe diameter, for each bend & welded them up. Took about 3 hours in all - quite happy as it lasted a year.

If trying tube bending, try hiring one from a tool shop. Make sure you use the correct formers to place the tube in - too big & you'll end up with a creased & flattened tube. If filling with sand, plug at each end & heat up prior to bending.

Before welding & bending etc, check out the cost of an aftermarket stainless replacement.

[This message has been edited by Steve Pickford (edited 23 November 2004).]
__________________
My photos: www.possu.smugmug.com
Reply With Quote
  #5  
Old 25 Nov 2004
Registered Users
New on the HUBB
  
Join Date: Nov 2004
Location: Fairbanks, Alaska, Alaska
Posts: 3
good info! i have access to these tools but am pretty green when it comes to metal. also have a broken sub-frame to weld back together and rienforce but i would probably slaughter it. any tips on type of metal and where to beef frame up.
thanks,
wade
Reply With Quote
  #6  
Old 26 Nov 2004
Steve Pickford's Avatar
Contributing Member
Veteran HUBBer
  
Join Date: Jul 2003
Location: Oxford, UK
Posts: 994
Quote:
Originally posted by wade f:
good info! i have access to these tools but am pretty green when it comes to metal. also have a broken sub-frame to weld back together and rienforce but i would probably slaughter it. any tips on type of metal and where to beef frame up.
thanks,
wade
Not really familiar with your bike re: beefing up the sub-frame. Just bear in mind that the sub frame on most bikes is subject to two forces.

The top rail that the seat rests on is normally subject to extension forces i.e. the force of riders weight & luggage tries to pull the tube away from the frame.

The lower subframe rail that is probably welded to the main frame somewhere near the swingarm pivot point is subjst to compression forces i.e. the weight is trying to squash the subframe.

Read Chris Scotts "Adventure Motorcycle Handbook" - plenty of tips/do's & don'ts there for beefing up bikes for long trips.

Re: welding - practice on scrap metal first, preferably of the same kind that you're going to work with. I'd buy extra tube & practice with a spare bit to get the welders etting correct before burning holes in the real thing (lol - been there & done that...)

Remember to remove the fuel tank before welding & to disconevct the battery before carrying out any electrical welding (Mig/Tig/Arc/Heli-Arc) on the bike. Might be wise to disconnect the ignition box also & remove the carb if it contains fuel.

__________________
My photos: www.possu.smugmug.com
Reply With Quote
  #7  
Old 9 Dec 2004
Registered Users
New on the HUBB
  
Join Date: Nov 2004
Location: Fairbanks, Alaska, Alaska
Posts: 3
right on for the info, already have exhaust bandage for patch job, was running with vice-grip and bailing wire, couldn't use duct tape anywhere, too bad...
thanks again,
wade
Reply With Quote
Reply

« Previous Thread | Next Thread »

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now, and add your information if we didn't find you.

Next HU Eventscalendar

25 years of HU Events
Be sure to join us for this huge milestone!

ALL Dates subject to change.

2025 Confirmed Events:

Virginia: April 24-27
Queensland is back! May 2-5
Ecuador June 13-15
Germany Summer: May 29-June 1
CanWest: July 10-13
Switzerland: Date TBC
Ecuador: Date TBC
Romania: Date TBC
Austria: Sept. 11-14
California: September 18-21
France: September 19-21
Germany Autumn: Oct 30-Nov 2

Add yourself to the Updates List for each event!

Questions about an event? Ask here

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

Adventurous Bikers – We've got all your Hygiene & Protection needs SORTED! Powdered Hair & Body Wash, Moisturising Cream Insect Repellent, and Moisturising Cream Sunscreen SPF50. ESSENTIAL | CONVENIENT | FUNCTIONAL.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.



All times are GMT +1. The time now is 00:54.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top