I suppose it had to happen at some point. After 42,000* miles my header pipe rotted at the y-piece.
I initially thought it was the gasket (�20 OE) that had gone but upon inspection it was the stain less header that had succumbed to rot and I think also a slight misalignment from the factory as it appeared to have thinned and then sheered.
Repairs took me the best part of 5 hours and the main problem was the headers were stuck in the head where the alloy had corroded around the pipe. Eventually they came free but it was a real ballache of a job. I've made an enquiry as to the cost of the header pipe as my repair isn't ideal. I had stainless tube in the shed from other exhausts I've made but nothing small enough diameter so I had to cut a small band and sleeve outside of the two broken pieces before welding up.
I'm in two minds now as to either replace the repaired part, leave it be until it fails again or fabricate a new system from a decent grade of stainless like 316. The latter would obviously cost more and take longer but would mean I could make a slightly larger bore system and possibly run 2-2 all the way.
What the whole thing has highlighted to me as well is that I have been taking the integrity of the bike for granted and after 5 winters I think it's time to give it a decent stripdown and replace bolts and coatings where necessary, as well as applying more waxoyl!









*technically 41,994 as I was on my way to work at the time