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[ultrafxr]

So I am on a road trip on my '07 cuse last week and as I move the bike from the check-in area at the motel to the parking spot I notice the engine does not sound quite right.  Did not notice it while riding with my helmet on and ear plugs in.  I quickly find a pretty good exhaust leak at the rear cylinder at the bottom.  The next morning while it was cold I checked the nuts on the exhaust studs but found them pretty tight - could only turn them maybe 1/8 of a turn.

Not having time to mess with it and needing a couple other things done I took it to the dealer when I got home.  He just phoned me with the news that the D&D head pipe is cracked!  Hmmm, I've not heard of this before.  Anyone else ever had or known this to happen on any exhaust?

Doubt there is any warranty or goodwill adjustment since the system is four years and about 50k old.

[sadunbar]

So I am on a road trip on my '07 cuse last week and as I move the bike from the check-in area at the motel to the parking spot I notice the engine does not sound quite right.  Did not notice it while riding with my helmet on and ear plugs in.  I quickly find a pretty good exhaust leak at the rear cylinder at the bottom.  The next morning while it was cold I checked the nuts on the exhaust studs but found them pretty tight - could only turn them maybe 1/8 of a turn.

Not having time to mess with it and needing a couple other things done I took it to the dealer when I got home.  He just phoned me with the news that the D&D head pipe is cracked!  Hmmm, I've not heard of this before.  Anyone else ever had or known this to happen on any exhaust?

Doubt there is any warranty or goodwill adjustment since the system is four years and about 50k old.

I've had a Rinehart Tru Dual rear cylinder pipe crack where you describe...  I've never had an issue of any kind with my D&D pipes...

[Fired00d]

Just found this number when I did a search for "D&D Exhaust Warranty" - Warranty 817-834-0996. Couldn't find anything documented on "warranty" but never know until you call them.

 
Ride Safe,
Fired00d
 

[ultrafxr]

Thanks guys.  I'll make the call.  Guess it is a rare occurrence.  Lucky me!  LOL.  Not complaining though.  Just a thing.

The other issue I took it in for relates to starting the engine.  And they agreed with my diagnosis - the compensator needs to be replaced.  So I am taking this opportunity to upgrade to the SE comp and install the 30T tranny pulley/sprocket.  I bet it will be like an entirely new bike when I get 'er done.

[1sharprdkg]

Thanks guys.  I'll make the call.  Guess it is a rare occurrence.  Lucky me!  LOL.  Not complaining though.  Just a thing.

The other issue I took it in for relates to starting the engine.  And they agreed with my diagnosis - the compensator needs to be replaced.  So I am taking this opportunity to upgrade to the SE comp and install the 30T tranny pulley/sprocket.  I bet it will be like an entirely new bike when I get 'er done.

I guess I missed the memo! What is the benefit of changing to the 30T tranny pulley/sprocket? More TQ? Quicker off the line? Which pulley would my 09SEUC have? Sorry for the lack of knowledge. Thanks. Oh good luck with the pipe. 

[ultrafxr]

I guess I missed the memo! What is the benefit of changing to the 30T tranny pulley/sprocket? More TQ? Quicker off the line? Which pulley would my 09SEUC have? Sorry for the lack of knowledge. Thanks. Oh good luck with the pipe. 

Yes, there is a thread under the drive train section about the 30T sprocket "30 tooth and happy."  The early 6-speeds were really dogs off the line due to the gearing being so tall.  Later models were improved but some folks still want to gear them down a little more.

[Buckeye_Tuning]

I guess I missed the memo! What is the benefit of changing to the 30T tranny pulley/sprocket? More TQ? Quicker off the line? Which pulley would my 09SEUC have? Sorry for the lack of knowledge. Thanks. Oh good luck with the pipe. 

Your 09 already has the proper gear ratio.  This is aimed at 07-08s which were dogs off of the line.

[ultrafxr]

Here is a photo of the crack in my D&D Fatcat header.  At the weld below the rear cylinder - it cracked almost the entire circumference.  Sending photos to D&D and even after four years looks like they may help out.  Would be good if they do.

[ultrafxr]

Another.

[cvobiker]

Defiantly a manufactor mishap,,  they'll replace it 

[strokerjlk]

there pretty easy to weld. save you some time.

[BADBAGG]

Your 09 already has the proper gear ratio.  This is aimed at 07-08s which were dogs off of the line.

I switched my 09 to 30 tooth. If it already had proper ratio they must have missed mine that day, cause 1st gear was way to tall.

[SneakyPete]

Looks like your pipes were Jett Hot coated.  I had a Reinhart 2:1 pipe that cracked the same way that was coated as well.  Maybe just a coincidence, but perhaps the coating process affects the weld somehow.  I replaced with D&D, didn'y do the coating this time, no issues in 6 years. 

[kraut]

I got used to have to weld headers on (pre 09!) touring bikes approx. every 20.000 m ...

[ultrafxr]

Looks like your pipes were Jett Hot coated.  I had a Reinhart 2:1 pipe that cracked the same way that was coated as well.  Maybe just a coincidence, but perhaps the coating process affects the weld somehow.  I replaced with D&D, didn'y do the coating this time, no issues in 6 years. 

Yeah, had it coated last year and only about 10k after it was coated.  Don't know why that would/could be an issue but who knows.  

Leonard said broken front motor mount could lead to this sort of failure.  But mine has been replaced and was just in the shop and checked as good so that does not seem to be an issue.