Author Topic: exhaust header 2002 concours  (Read 731 times)

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Offline 1976kz

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exhaust header 2002 concours
« on: July 14, 2019, 02:13:37 pm »
I've got a small hole in the header cross over pipe from rust, so I am looking for a decent used header. (r&L)  Also, I plan on removing the exhaust myself, seems fairly straight forward but are there any tips anyone can give me to make it easier?
My bike is a 2002 with 54,600 miles.
thanks,
mark

Offline Boomer

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Re: exhaust header 2002 concours
« Reply #1 on: July 14, 2019, 04:19:26 pm »
You can take it off pretty easy. Only difficult bit is removing the rad.
Once the headers are off, take them to a local exhaust specialist and they can weld new tube in place of the holed sections. Probably cost ya $50.
Mine has stainless headers from Motad, but they weren't cheap and they no longer make them.
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Offline crag antler

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Re: exhaust header 2002 concours
« Reply #2 on: July 14, 2019, 06:05:03 pm »
As boomer said it is easy. Good reason to get a factory service manual. When I did mine earlier this year,for the same reason. I purchased all new exhaust gaskets. Also had the “new/used” ‘06 header ceramic coated but not cheap either, but supposed to cut heat by 60%.
If I ever get the bike going, I’ll let you know. ;)
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Offline MAN OF BLUES

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Re: exhaust header 2002 concours
« Reply #3 on: July 14, 2019, 10:04:25 pm »
I've got a small hole in the header cross over pipe from rust, so I am looking for a decent used header. (r&L)  Also, I plan on removing the exhaust myself, seems fairly straight forward but are there any tips anyone can give me to make it easier?
My bike is a 2002 with 54,600 miles.
thanks,
mark

that small hole you see, on the bottom of the cross over pipe,  is always there, even on a new pipe...
it is essentially a drainage hole, to allow water vapor to drip out..it's at the lowest part of the exhaust system and there for a reason..
 It's only about 1/8" in diameter... no need to replace or mess with it, unless what you have is really a rotted out pipe, with a hole you can stick your finger in..  rust does accumulate around that hole, on the surface of the pipe, but it does not effect anything.
« Last Edit: July 14, 2019, 10:07:53 pm by MAN OF BLUES »

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Offline 1976kz

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Re: exhaust header 2002 concours
« Reply #4 on: July 15, 2019, 09:55:42 pm »
thank you for replying, good info!

Offline connieklr

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Re: exhaust header 2002 concours
« Reply #5 on: August 25, 2019, 02:31:59 pm »
I've got a small hole in the header cross over pipe from rust, so I am looking for a decent used header. (r&L)  Also, I plan on removing the exhaust myself, seems fairly straight forward but are there any tips anyone can give me to make it easier?
My bike is a 2002 with 54,600 miles.
thanks,
mark

that small hole you see, on the bottom of the cross over pipe,  is always there, even on a new pipe...
it is essentially a drainage hole, to allow water vapor to drip out..it's at the lowest part of the exhaust system and there for a reason..
 It's only about 1/8" in diameter... no need to replace or mess with it, unless what you have is really a rotted out pipe, with a hole you can stick your finger in..  rust does accumulate around that hole, on the surface of the pipe, but it does not effect anything.

"that small hole you see, on the bottom of the cross over pipe,  is always there, even on a new pipe..."

Okay l'il snowflake, you care to enlighten me/us just where that magic hole might be in the crossover pipe? Had plenty of pipes off and on, and never seen such a hole. Muffler(s) yes, crossover no.

?????????????









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Offline bajasam

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Re: exhaust header 2002 concours
« Reply #6 on: August 25, 2019, 05:36:37 pm »
Lil Snowflake, now thats a good one.......... :D ;D :D :rotflmao: :beerchug:

Offline MAN OF BLUES

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Re: exhaust header 2002 concours
« Reply #7 on: August 25, 2019, 06:59:46 pm »
Lil Snowflake, now thats a good one.......... :D ;D :D :rotflmao: :beerchug:


I'll caution you ONE time... about calling names, as you do not know me; Guy can say what he wants, being about as good of a friend as a person can have.. and he and I can joke... you do not have that liberty... get it?

I've got a small hole in the header cross over pipe from rust, so I am looking for a decent used header. (r&L)  Also, I plan on removing the exhaust myself, seems fairly straight forward but are there any tips anyone can give me to make it easier?
My bike is a 2002 with 54,600 miles.
thanks,
mark


that small hole you see, on the bottom of the cross over pipe,  is always there, even on a new pipe...
it is essentially a drainage hole, to allow water vapor to drip out..it's at the lowest part of the exhaust system and there for a reason..
 It's only about 1/8" in diameter... no need to replace or mess with it, unless what you have is really a rotted out pipe, with a hole you can stick your finger in..  rust does accumulate around that hole, on the surface of the pipe, but it does not effect anything.


"that small hole you see, on the bottom of the cross over pipe,  is always there, even on a new pipe..."

Okay l'il snowflake, you care to enlighten me/us just where that magic hole might be in the crossover pipe? Had plenty of pipes off and on, and never seen such a hole. Muffler(s) yes, crossover no.

?????????????




Guy, I've been searching for the photos I took of the specific hole, they exist up on my ancient PhotoBucket account, and I can't get them, I do have pictures somewhere else, I know I do, as I have posted them in the past...

edit;... found it....
http://forum.cog-online.org/concours-c10-zg1000-general-chat-and-tech/is-there-a-drain-hole-in-the-exhaust-at-the-crossover/msg556657/#msg556657

Nice of PhotoBucket to conveniently place thier watermark over it... but it still can be seen, as in the picture I added.. with another arrow... below.

One of you pictures shows the spot, but on your crossover that hole seems rusted shut... poke it with a nail, and I bet that center "plug of rust" pops right out...
My pic's were of both my '86 and COGZilla '88 bike, and without crawling under a pile of stuff right now, I can't shoot a fresh one for ya.. but I know both pipes had that small hole there.. it was located on the bottom of the pipe, right where it's visible in the picture I added the arrow to below.
« Last Edit: August 25, 2019, 07:17:42 pm by MAN OF BLUES »

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Offline Jim Snyder

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Re: exhaust header 2002 concours
« Reply #8 on: August 25, 2019, 07:20:40 pm »
My 02 stock pipes/mufflers had the weep holes in them. They are there to allow moisture to exit the pipes to prevent corrosion. Many times when I cranked it up it would drop water out of those holes.
"Some days you're the windshield, and some days you're the bug" Get used to it cause thats life !!!

Offline connieklr

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Re: exhaust header 2002 concours
« Reply #9 on: August 25, 2019, 07:35:19 pm »
Nope - nothing but rust craters/pockets. Poked several with the point of a finishing nail, and they were solid.





The loose, (relatively) clean pipe showed no evidence of any hole either.
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Offline MAN OF BLUES

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Re: exhaust header 2002 concours
« Reply #10 on: August 25, 2019, 07:52:57 pm »
 :)) :)) :)) :)) :))

Well, I guess I had 2 defective crossovers, and the other 2 people that noticed them did also...  ;) :) :beerchug:

http://forum.cog-online.org/concours-c10-zg1000-general-chat-and-tech/is-there-a-drain-hole-in-the-exhaust-at-the-crossover/msg556657/#msg556657

I dunno brother, it's a mystery of the universe....  :rotflmao:

now, go drill a hole in there so this one doesn't rust out like your old one did... :rotflmao: :nananana: :nananana: :rotflmao:

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Offline Pbfoot

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Re: exhaust header 2002 concours
« Reply #11 on: August 26, 2019, 07:44:45 am »
Can confirm my 06 has a drain hole in the crossover as did my friends 05 that I worked on.
If you don't have time to do it right, when do you have time to do it over.                                                                17" wheels, Nissin 4 piston calipers.1kg Sonic Springs.Cartridge Fork Emulators. KB Brace. Galfer brake lines  Free power mod.

Offline connieklr

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Re: exhaust header 2002 concours
« Reply #12 on: August 26, 2019, 08:55:48 am »
Admittedly, I have no idea what year bikes my two non-hole examples are from. Do know my '95 does not have the drain hole. So, can only assume Kaw added them at some point in the production run.

Carry on........
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Offline bajasam

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Re: exhaust header 2002 concours
« Reply #13 on: August 26, 2019, 05:13:21 pm »
No warning needed as I called you nothing, connies little pet name for you simply made me laugh out loud and I found it very humorous, if your insecure about having such a cute nickname you need to discuss it with Mr.Connie, your threats have no meaning to me as your no more than a bothersome gnat to me.I do hope the moderators have the integrity to warn you about your behavior though.Back on track though my 04 has no drip hole either.

Offline Bob_C_CT

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Re: exhaust header 2002 concours
« Reply #14 on: August 26, 2019, 07:37:43 pm »
My 97 does have the drip hole.
Southern Connecticut.
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Offline MAN OF BLUES

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Re: exhaust header 2002 concours
« Reply #15 on: August 26, 2019, 09:51:52 pm »
My 97 does have the drip hole.

Thanks, and I'll say I'm not dissing Guy, as he is my pal, but he may have a point as to some "changes" that occurred, I know the early models I had/have, also had weep holes.. he did buy replacements a while back, which I remember, to repair his bike.  Don't know what year they actually came from.  He and I hoarded many parts over the years.. we're funny like that...  :rotflmao:

also,
tell it to Bajasam.... so he will quite stalking me.. which is a thing that I don't like....  ::)
« Last Edit: August 27, 2019, 07:33:37 pm by MAN OF BLUES »

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Offline bajasam

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Re: exhaust header 2002 concours
« Reply #16 on: August 27, 2019, 05:02:03 pm »
Well Lil'One, I'll tell ya, I have no  issues with my masculinity nor any insecurities, so if you and your amigos can have a good laugh at my expense then have at it, I'm more than happy to be your target as this world can use all the humor and joy it can get. This is for you  :rotflmao: :rotflmao: :rotflmao: :rotflmao: :rotflmao: :rotflmao: :rotflmao: :rotflmao: :rotflmao: :rotflmao: :rotflmao: :rotflmao: :rotflmao:

Offline connie_rider

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Re: exhaust header 2002 concours
« Reply #17 on: August 27, 2019, 10:00:57 pm »
My 2003 does not have the holes.

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Offline connieklr

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Re: exhaust header 2002 concours
« Reply #18 on: August 29, 2019, 07:22:29 pm »
Would be interesting to know if the crossover drain holes have a positive affect to eliminate, minimize, or prolong pipe life.

The rusting I've seen all seems to be external, and the crossover just seems to go away from there. Granted, no way to know what's going on inside unless you pull the headers so they can be separated. Not a fun job to do just for grins.
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Offline MAN OF BLUES

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Re: exhaust header 2002 concours
« Reply #19 on: August 29, 2019, 08:30:50 pm »
Would be interesting to know if the crossover drain holes have a positive affect to eliminate, minimize, or prolong pipe life.

The rusting I've seen all seems to be external, and the crossover just seems to go away from there. Granted, no way to know what's going on inside unless you pull the headers so they can be separated. Not a fun job to do just for grins.

can't say for sure, but both mine looked pretty nice, even as old as they were.. the '86 was the one I attached that picture of, when I installed the SPOOFAK mod, but as you can "kinda see", that pipe seemed pretty rust free and was not rotted out..
Same on the '88,
with the cost of those replacement muffler & crossover gaskets, I always tried to "maintain them carefully",  :rotflmao: :rotflmao: they aren't cheap.. but I always keep a pair of them on hand.  Wouldn't normally risk $35 just to "peek inside" the crossover myself.  :rotflmao: :rotflmao: :rotflmao: :great: :great: :great:

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Offline connieklr

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Re: exhaust header 2002 concours
« Reply #20 on: August 30, 2019, 09:23:31 pm »
I am 99% sure all three of my rusted thru exhaust systems (GPz 750, ’86 and ’95 Connies) was the result of my riding the bikes in all kinds of weather just about every day that I’ve had them, especially when I was commuting back and forth to work every day. The two Connies have also been through flooded roadways, axle deep, on several occasions….. here in Richmond, and over along Rte. 52 in WV.

Can’t prove it, of course, but still think they all went away, starting from the outside in. No regrets. All of my bikes have been used for the way they were intended to be used.
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Offline MAN OF BLUES

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Re: exhaust header 2002 concours
« Reply #21 on: August 30, 2019, 09:51:33 pm »
I don't dispute any of that.... for sure..   :great: :great: :great: :great:
(if it wasn't for you, I'd never have had a Conni, an Aerostich, a Heated Gerbing, or even the propensity to look at non riders and say "rain?... hell.. it's just water....")   :great: :great: :great: :great: :beerchug: :beerchug: :beerchug:

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and if you are gonna call me names... it's MR. Analdweeb if you please...