SuzukiSavage.com - Welp, my exhaust fell apart!

och

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Welp, my exhaust fell apart!
03/07/23 at 17:12:22

And I have noone to blame by myself, lol. So back in 2016 when I first got my S40, which was my first bike, one of the first mods I installed a Dyna muffler. I tig welded it to the stock header, but the connection between the two pipes looked sloppy, so I decided to wrap that section with heat wrap. Turns out it was a mistake.

Today I was riding, and mid ride the exhaust started rattling and popping. Look down, and sure enough, the connection rusted and separated, even ripped the heat wrap. I guess the heat wrap was staying wet all the time since I keep the bike outdoors, which caused the rust to slowly eat through the weld and the sleeves. I can't take a photo of the damage right now since my phone camera is broken, but here is the "before" photo of the bike.

Either way, I will try to deal with it next week sometime, will grind off the rusted section and weld on a new section. Going to measure the diameter and try to use stainless pipe to avoid future rust.

That being said, right now the bike sounds awesome with whats essentially a straight pipe, and I have not noticed any performance drop other than the crazy amount of popping on decel. I am almost contemplating doing a straight pipe now.

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och Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 616	Re: Welp, my exhaust fell apart! Reply #1 - 03/07/23 at 17:18:39 You can kind of see in this photo the connection. I don't have any better photo right now.
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J Mac Senior Member Offline Laissez Les Bon Temps Roulez Posts: 386 Louisiana, USA Gender:	Re: Welp, my exhaust fell apart! Reply #2 - 03/07/23 at 17:55:08 That's the color scheme of my 2012. I don't know if I'm going to mess with a Dyna muffler. I might leave the stock one on, given this will be a low miles bike.
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pg Serious Thumper Offline Posts: 5273 In Transit	Re: Welp, my exhaust fell apart! Reply #3 - 03/07/23 at 18:14:47 The baffle blew out of my dyna at some point. The rumbles and backfires give it some character; however, it is pretty much a straight pipe. I have to wear ear plugs or it is really unpleasant. Best regards,
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och Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 616	Re: Welp, my exhaust fell apart! Reply #4 - 03/07/23 at 18:26:50 J Mac wrote on 03/07/23 at 17:55:08: That's the color scheme of my 2012. I don't know if I'm going to mess with a Dyna muffler. I might leave the stock one on, given this will be a low miles bike. The Dyna sounds much much better than stock, totally worth it.
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och

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Re: Welp, my exhaust fell apart!
Reply #5 - 03/07/23 at 18:27:24

pg wrote on 03/07/23 at 18:14:47:

The baffle blew out of my dyna at some point. The rumbles and backfires give it some character; however, it is pretty much a straight pipe. I have to wear ear plugs or it is really unpleasant.

Best regards,

Yeah, thats what I fear, it might be fun for a while but will get annoying quick.

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pg Serious Thumper Offline Posts: 5273 In Transit	Re: Welp, my exhaust fell apart! Reply #6 - 03/07/23 at 18:39:31 Unpleasant is really an understatement., it will likely cause some hearing loss. The dyna really has a nice note. I ordered a pair on ebay and looked forward to putting one on. Best regards,
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J Mac

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Re: Welp, my exhaust fell apart!
Reply #7 - 03/08/23 at 16:47:17

I know this has been covered extensively, but did YOU personally rejet because of the Dyna muffler?

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och wrote on 03/07/23 at 18:26:50:

J Mac wrote on 03/07/23 at 17:55:08:

That's the color scheme of my 2012. I don't know if I'm going to mess with a Dyna muffler. I might leave the stock one on, given this will be a low miles bike.

The Dyna sounds much much better than stock, totally worth it.

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J Mac Senior Member Offline Laissez Les Bon Temps Roulez Posts: 386 Louisiana, USA Gender:	Re: Welp, my exhaust fell apart! Reply #8 - 03/08/23 at 16:48:05 Did you rejet after putting the Dyna on? -------- pg wrote on 03/07/23 at 18:39:31: Unpleasant is really an understatement., it will likely cause some hearing loss. The dyna really has a nice note. I ordered a pair on ebay and looked forward to putting one on. Best regards,
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pg Serious Thumper Offline Posts: 5273 In Transit	Re: Welp, my exhaust fell apart! Reply #9 - 03/08/23 at 17:23:45 I did, the main jet went up a bit. Here is a thread with a lot of good information. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1309246277 Best regards,
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SpamyToo Full Member Offline Posts: 231	Re: Welp, my exhaust fell apart! Reply #10 - 03/08/23 at 17:24:31 Sorry to hear that. I had put a post up before about pipe wrap being a ticking time bomb. I had a pipe totally disintegrate because the wrap. The rust went crazy, and the contained heat melted some of the metal. Yeah the carb was a bit out of balance then, but the wrap was the catalyst that ruined that pipe.
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och Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 616	Re: Welp, my exhaust fell apart! Reply #11 - 03/08/23 at 17:33:08 J Mac wrote on 03/08/23 at 16:48:05: Did you rejet after putting the Dyna on? I have not. I have zero experience with carburetors other than remembering my grandpa curse the carb on his ZAZ968 needing repairs every 50 miles or so.
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och

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Re: Welp, my exhaust fell apart!
Reply #12 - 03/08/23 at 17:34:11

SpamyToo wrote on 03/08/23 at 17:24:31:

Sorry to hear that.

I had put a post up before about pipe wrap being a ticking time bomb. I had a pipe totally disintegrate because the wrap.

The rust went crazy, and the contained heat melted some of the metal. Yeah the carb was a bit out of balance then, but the wrap was the catalyst that ruined that pipe.

Yep. I am yet to take it off to assess the full extent of the damage, it wont surprise me if I'll be in for a new header pipe.

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och Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 616	Re: Welp, my exhaust fell apart! Reply #13 - 03/09/23 at 15:33:42
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pg Serious Thumper Offline Posts: 5273 In Transit	Re: Welp, my exhaust fell apart! Reply #14 - 03/09/23 at 16:00:48 Did that break at the front of the muffler? The header pipe goes in about 2 inches. Best regards,
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