XT600e Rotted Downpipes
 

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!

Post some pics.

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

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

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.

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!

Thanks for all your advice, i'm going to try tomorrow and see what happens!

Use a generous amount of copper slip on and around the exhaust gaskets and also on the exhaust studs when installing the new ones.

This will considerably help to prevent this happening again in the future.

If I was keeping my xt600 bike a long time I would of probably drilled and tapped out the exhaust studs to an M8 as the current M6 cheese bolts are a joke.

:thumbup1:

Hi, I decided to overhaul my XT600E and have hit the same problem, sawed the down pipes off and now need to take out the engine to somehow remove the engine end of the exhaust. Fitting new rings and valve stem seals, anything else I should do whith the engine while it's out. Andy

I don't think you need to take the engine out? not 100% on a 600E though? with the older bikes you can tilt the engine forward by removing the front bolts & leaving the main bolt that goes through the swingarm.

Mezo.

On mine (3TB, 1994) I was able to take the head off without moving the engine. It needs a bit of wiggling to get the cam covers past the frame, but it's quite possible. Obviously, tank, coil etc need to be removed first.

Don't you have a gear puller? or get a damn file , put a groove on the seal and pull it out... use vice grip pliers...

Or use a carbide burr (ball shape) thats how we used to remove valve seats, cut a slot & then fold the seat inwards & out she popped.

http://richontools.com/images/categories/071036.jpg

Mezo.

I tried those. It's not just the seal. On mine (and I think on the OP's) it is the exhaust pipe boss that is stuck. You can't cut a slot in it without damaging the head casting around it. And it's too small to get a gear puller inside (at least, none of mine would fit in there). Once the boss is out, the gasket is easy. But those exhaust bosses are big solid things, and corrode into the head very effectively.

I gave it a day and a half on the bench with every tool I possess, and I had to give in eventually.