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Patching Hole in Stock Exhaust

Discussion in 'XJ Technical Chat' started by corgitwo, Nov 30, 2008.

  1. corgitwo

    corgitwo Member

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    Hello everyone. My 1982 XJ650J has a hole in each muffler section just behind the crossover-looking piece. The hole is on the bottom and small. Any ideas on how to patch it? And would the exhaust leaks make idling slightly rough?
    Thanks for the help
     
  2. danno

    danno Member

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    If it is a rust hole,repair it. If it is a perfectly round hole in the same spot on each muffler,it is a drainage hole (engineered by the manufacturer) to evacuate condensation that forms inside the mufflers.
     
  3. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    If the holes are indeed perfectly round and look like they really should be there (drain holes) but DO have exhaust leaking out of them, you may have an internal crack in the piping inside the mufflers. If that's the case you can go ahead and plug them if you really feel the need. A tiny exhaust leak that far back shouldn't affect how the bike runs, unless the muffler internals are all busted up. You might want to go ahead and take the muffler(s?) off and simply shake them. You'll know immediately if anything big has broken or come loose inside. I have a nearly perfect LOOKING Seca 550 muffler that sounds like a whole junkyard is rattling around inside.
     
  4. brent_bastien

    brent_bastien Member

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    i have a holy exhaust as well what should we use to patch the holes
     
  5. Fongdingo

    Fongdingo Member

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    i used jb weld and a soda can, easy and it worked well, i cleaned and sanded the area and cut a pice of soda or beer can and fixed it. worked well and mae the bike more quiet.
     
  6. corgitwo

    corgitwo Member

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    So, JB Weld will bond a aluminum pop or beer can piece to Steel? It's worth a try. It's under the bottom of the exhaust and almost needs a mirror to see it. I considered welding it, but if the whole area is thin from rust, welding would be a difficult option.
    Thanks
     

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