Viper Exhaust Manifold Hairline Crack

ryanryan

ryanryan

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Southern Ontario, Canada
I have a hairline crack in my manifold. Do you think it is affecting anything, like performance or back pressure? I am looking for some on ebay and craigslist and found a couple for $100, do you think it is worth it to replace or just leave it and wait till I notice a performance loss or extra oil usage. I was considering welding it but don't know if it is worth it.
 

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Yeah just weld it. Mine did the same thing on the top and bottom side, although i let mine get til it was much worse. I welded it and it hasnt been an issue.

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That seems to be the way to go. The guy i bought mine from said this happens to them all at one point. mine are welded and painted and work good as new.
 
this can be caused by a number of problems such as a bad exhaust gasket b/w pipe and manifold, excessive engine torque from a bad/loose motor mount or lack of torque limiter. it can be welded but will probly crack again, and again...check the exhaust gasket as it prolly needs replacing.
 
Is that a pretty easy weld? the steel isn't that thin or anything right? I'm having a buddy weld it for me, his only concern (over the phone without seeing the manifold) was that it might burn through. It seems pretty straight forward...
Any advice on what paint works? rust-oleum high heat? How hot do you think the manifold gets?
 
Stove paint will not burn off. If not high heat header paint.
 
its easy enough to weld, ive done a bunch of em, some my own and some others. its very common. dont overlook the things bolin22 sugested, they are also common problems and could very well cause it.
 
Just make sure that who ever welds it, that they drill out the ends where the cracks end, to start/end the welds. This helps prevent the crack from spreading any further.
 
Welding that manifold is a piece of cake. If you were in my region I would take care of it for you for free. I have welded a bunch of them. I grit blast the outside and inside of the manifold to clean off the rust and carbon. The crack gets welded with the TIG process and a high strength filler rod. The last step is to either ceramic coat it (preferred) or painted with a high temp paint.
 
SRX500kid said:
do you think it will happen to my 2000 sx500r twin?
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I don't think it will, this is a common problem on the Viper's though, both of our 05's did this between 1500-2000 miles
 
Get ceramic coated triple pipes on there and get rid of that rusty exhaust manifold. Or else remove that manifold, sand blast it and weld/ fix the crack and then ceramic coat the manifold so it doesn't get all rusty like that again.

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;)!
 
thank you for the weld advice and paint advice.

How do you know when you need to replace the exhaust manifold main gasket?
The one I just pulled off of mine is three thin pieces, is that normal? I expected it to be just one gasket, not three thin stacked pieces of metal.
It did seem to get pretty dirty in that section of the engine compartment . The manifold cracks were not dirty though.
 
SXlover said:
I don't think it will, this is a common problem on the Viper's though, both of our 05's did this between 1500-2000 miles
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Never seen an 05 Viper, must have been the last year for them and the rest of the Yamaha 2 stroke line?
 
LaPorte429 said:
Never seen an 05 Viper, must have been the last year for them and the rest of the Yamaha 2 stroke line?
Click to expand...

They made a 05 and i think even a 06 mountain viper only, last of the 2 stokes. Not sure on the 06.
 
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