Cracked header pipe

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bud500 (R.I.P)

Grey Hound
Joined
May 11, 2006
Messages
5,545
Reaction score
2
Location
Pretoria East
Bike
KTM 990 Adventure
I've got a 2008 990 S, owned since new, with about 50 000km on the clock.

The bike has never been in a crash apart from 3 or 4 low speed falls offroad.

A few weeks ago I thought I started imagining a noise coming from the motor. As if the engine was a bit louder.
Initial reaction was maybe the valves need adjusting. After closer inspection, with the engine running, I was happy that the noise was not from the engine it self.

My next thought was either the airfilter was somehow unseated or the exhaust was loose. Both these were incorrect.

The festive season came and went with no riding  ::) so yesterday I took the bike out for a quick ride. There the noise was again, but a bit more obvious, to me at least. The bike just didn't sound crisp and solid.

After some more thorough inspection I found the rear exhaust header coming from cylinder 2 was severely cracked in the bottom of the u-bend either side of the lambda sensor... :eek:

The whole exhaust system is still secure and has no movement.

I have not seen this issue on these bikes before.

Does anyone have a suggested solution, excluding breaking the bank at the Dealer?  ???
 
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