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

Howdy Tom,


Yes.... me too. I started in the Spring, but I've still to give her an ACF bath. So I guess it'll be a partial strip down of body parts and some application of TLC over the coming weeks.

Good thing is, it doesn't take long.

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Never underestimate the power of stupid people in large groups.

Blimey, what a co-incidence. I've just got off the phone from another Tenere owner and the 'Y' piece just after the headers has blown an inch dia hole in it! Clean through the plastic shield! He has scourced another but was asking me about a single sided silencer. I told him that even a single has need of the 'Y' piece.
..............and as he is a mate I told him that I've taken my single silencer off and gone back to the original as the MTC is TOO LOUD, so I wouldn't sell it to him in any case.

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If I'm not working, I'll be

Hey Steve. I ordered the replacement part from here https://www.motorcyclespareparts.eu/...st-357480.aspx as it was a reasonable price. Good luck to your buddy.