Salvagable exhaust? - Honda Rebel Forum
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post #1 of 4 Old 01-14-2020, 06:43 PM Thread Starter
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Join Date: Apr 2014
Location: Ft Stewart
Posts: 86
Salvagable exhaust?

As you can see from the pic, the right side exhaust was broken at some point prior to me getting the bike. It was laid down on that side enough where both turn signals lenses were broken.

Someone tried to weld it, but only did a tack weld on the bottom and only weld the half of the pipe that faced outward. It looks like they ran the bead to quickly and it didn't stick to one side.

I'm thinking it's probably not salvageable as far as returning it to a stock configuration. As it stands, it vibrates horribly over 45 mph and isn't creating near enough back pressure in the cylinder. That spark plug is covered in soot.
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2001 Honda Rebel 250
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post #2 of 4 Old 01-14-2020, 10:28 PM
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You can weld it correctly, and it will be functional but probably not pretty, if that is a concern. Is the crossover connector pipe still there? It helps performance. Used exhausts are frequently available on ebay.

Keepin' all the left over parts. Gonna use 'em to build another bike!

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post #3 of 4 Old 01-15-2020, 01:46 PM
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Can you fully remove the outer chrome pipe? It looks like you have another break in the inner pipe.

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post #4 of 4 Old 01-16-2020, 03:25 PM Thread Starter
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Join Date: Apr 2014
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Yeah. The muffler is fully broken. The inner pipe is broken probably 2 inches into the outer pipe. The only thing keeping the muffler in place is where it bolts to the frame.

The crossover connection is still good. I had to unbolt it to get the right side pipe off the manifold. The thing is, I wasn't sure if only welding the outer pipe would create the correct amount of back pressure to keep the cylinder from fouling.

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