KX500 UPPER RIGHT EXHAUST PIPE HANGER BRACKET IS BROKEN, FIX IT

[Sandblaster]

So your upper right exhaust mount has broke off.
You know, the one by the coil...
Join the club

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There are many, many, different ways to fix it.
I like this method the best.
It is quick, easy to do, and best of all CHEAP!!!
First, do not remove the existing mount as you will use it as a guide later on.
Also, you will need it to make your paper template for hole position.

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Yeah, I made mine on CAD so I could print it out as I have used the template many times

Next, I take some 1" square tubing 1/8" wall.
I mark it and cut it...

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Once I get it close to where I want it, I clean it up a bit.
Nothing crazy although you could if you wanted to.

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[Sandblaster]

Laying the new bracket over the existing mount I use my paper template over the mount and mark the hole.

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You don't have to do this but you can weld a small piece on the inside of the bracket.
Doing this gives you more meat to drill and tap into. This will allow you to skip using a nut with the hanger bolt.
But, you can still use a nut if you choose to do so.

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Because Jason and I replace a lot of these Jason made a aluminum hole position finder.
It is not necessary as you can use the paper template...

[Sandblaster]

Hopefully uou can weld better than me... I'm a grinder, not a welder..

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Again, there are many other ways to do this but for me it is simple and easy to do.
I will eventually show some other ways that this is being done...

[Sandblaster]

This is a link to Jason Tanners video on frame gusset kits.
Watch the vid and prepare to pause it.
He uses a custom made piece that you can see in the vids.
It's a lot more work but has a custom look to it..


https://www.youtube.com/watch?v=pL6MqT8Iox0

[Sandblaster]

Here is another method..
Get a piece of 1/8" mild steel and form it so that it fits over the existing bracket and weld it on.

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[Lcgordon711]

Any chance anybody would have a pdf or something for the paper template to email me or post. I would really like one.
Thanks

[Sandblaster]

This page shows 3 different styles.
Which did you want?
Or are you wanting the template for the hole spacing?

[Lcgordon711]

Thanks and the paper for the hole spacing. I think the square tubing way is what I am going to go with. Just not sure distances on the paper and the hanger on the bike is too bad to see where the existing hole is to measure off of.