XT600e Rotted Downpipes

[nickyboy4]

The downpipes which i've just removed off my xt600e were rotted into place and have snapped leaving a sliver of metal sticking out of the exhaust ports. Not being the best mechanic around i can't tell whether the shoulder of the new downpipes i'll be getting will slide into the port or just be a flush fit. Trying to avoid an engine out job if i'm honest to get the residue of rusted metal out!
Any advice appreciated!

[frozenbiker]

Post some pics.

[bianchi]

Hi i have just done this job you are better to get the engine out and on the bench it took about 3 hours with lots of heat to get them out

your new ones slide into the exhaust port for about an inch

cheers

Dave

[nickyboy4]

Thanks for that, that's all i need to know!

[Mezo]

If there is any left sticking out use a small chisel (not wood one) and bash it inwards so it folds inwards on itself, or use a decent flat HD screwdriver.

Also make sure you get all of the copper gasket out before fitting your new ones or it will leak if you put new gasket over old flattened ones.

Mezo.

[BlackDogZulu]

Same happened to me, and I totally failed to get them out. I took the head off and had it on the bench. Chisels, dremel, blowtorch, 2lb sledge, nothing would shift it. I ended up taking it to a mechanic as a last resort, something I haven't had to do in years. It took him about an hour with an oxy torch, basically burned them out of there.

Getting the new ones in is easy. They are a nice sliding fit in the ports. Get the old copper gaskets out and clean the mating surfaces for a good seal. If it's scabby in there, the gaskets may not be obvious, but a chisel or big screwdriver will help. They don't always want to come out!

I put new studs and bolts in at the same time, and the Motad downpipes are great. They were shiny for about ten minutes before they began to go a straw colour, and by now they are dark coppery brown. But no rust!