I was going over my 599 and discovered a broken arm from the headers to the frame under the bike. Check it...
http://www.slidedesigns.com/files/arm_break.jpg

My bike has lived a life of luxury... never dropped, never hit anything from underneath so I have no idea how this happened.

What the hell. I bought an extended warranty (I'll never do that again) and of course it is not covered. So my 2 options are replace the headers or weld the joint back together.

Has anyone experienced this? Any opinions on what course I should take?

'Preciate it!!!

slide my 06 did the same thing went to the dealer and they gave me a brand new set of headers under warranty...... the weld was burned a lil too deap and it fractures from vibrations and such..... if its still under warranty they should do the same for you thats ridiculous that they wont
all they did was make sure there were no dents and that I did not smash the headers or anything that would have made it my fault and since there was none it was a defect in manufacturing ...... I am good friends with my dealership so dont know if that has to do with it or not but still

If the part is steel take it to a local muffler shop and they should weld it up for you for a few bucks.

Yeah, just get it welded back together... easy fix.

its stainless so a regular weld will rust dont let a yahooo do it

Well that's a bummer... :? If possible, try another dealership and see if they'll cover it. Try calling Honda. Don't give up that easily. Good luck.

Thanks guys. Well, I was a little more "persistent" with the dealer and they have contacted Honda and are going to send them the pic and try and set me up with a new set of headers.

Worse case scenario I have it welded... but as most of you can appreciate, I'd rather have everything perfecto than use a band-aid solution!

BTW, Steve am I using the right terminology for the part?

sorry to bring up an old topic but i thought it was better then making a new one. i just found that that exact same part is broken on mine. mine is cracked on each side though. look:
http://i167.photobucket.com/albums/u135/93conover/right.jpg

sorry about the pictures i suck at this whole taking pictures thing. i know mine won't be warranty (second owner) so it'll definitely have to be welded. I've already been to a muffler shop and the guy told me that since it's a bike he wasn't touching it! i asked him why and he said something like this: no, not touching it.....eh.. computer.... not welding bikes. so rather then having some moron try to weld it, i left. I'll get someone to weld it elsewhere.

here's a better picture.
http://i167.photobucket.com/albums/u135/93conover/right-1.jpg

He is worried about frying your bikes "computer" brain with an arc welder... Honestly I'm with him. Could always remove the parts, either the computer - whatever that is, or the header and bracket.

Anyone ever watch that Long Way Round (http://en.wikipedia.org/wiki/Long_Way_Round) show with Ewan McGregor (http://en.wikipedia.org/wiki/Ewan_McGregor)? His camera man's bike was killed with an arc welder. And because of that show, I always fill up with my helmet on and visor down.

Anyone ever watch that Long Way Round (http://en.wikipedia.org/wiki/Long_Way_Round) show with Ewan McGregor (http://en.wikipedia.org/wiki/Ewan_McGregor)? His camera man's bike was killed with an arc welder. And because of that show, I always fill up with my helmet on and visor down.

Long Way Round is an absolutely fantastic, as well as entertaining, series. Some day I hope to own it , rather than just borrow it.

-FT3

I read the book, never saw the show. I enjoyed the travel descriptions, but I think Ewan McGregor came off as kind of a prick, especially when he got to Alaska and started trash-talking my home town. :evil:

I got lucky with mine ...happend early before I had alot of miles

I got lucky with mine...
That's a very healthy perspective...

All these weld issues... 2006's?

Mine is a 2004.

The best approach (apart from getting new headers!!!) is to remove the whole thing, get it welded by a pro, then replace the gaskets and get 'er back on.

04 as well. how hard is it to remove the headers? just about how long does it take?

It's pretty straight forward. Download the shop manual PDF and there is a step-by-step guide to removing and re-installing the header pipes. Make sure to use new gaskets when you put them back on!

You're looking at under an hour if you take your time... also make sure to use the recommended torque values that are listed in the shop manual.

Issues before or after replacing the stock pipe?

still the stock pipe, never touched it. i have 16000 km on it right now, but i think it's been broken for like 3000-4000 km. there has been an unexplained buzzing sound between 4k-4.5k rpm for a little while now. i think i just found why.

I just noticed that both the bracket arms on mine are completely broken! The exhaust system is not loose, though, so I'm in no hurry to remove the headers for the weld job. And I have a friend that is a very good welder!

Bummer! Looks like it's a 2004 issue... apparently Honda was helping out in the model year but now claim ignorance of the problem. Just a reminder, if you're going to do a weld, I'd recommend removing the system first.

Man, is it ever a good excuse to get a new set of nice fat Hindle pipes! :wink: