hole in the muffler — leaking exhaust — best way to fix it?

[Toner]

Was going to ask you nice people here how to get the muffler guard off as I thought it was covering the leak I noticed earlier but I went back down to capture some video of my problem with the bike running and took an undershot. It appears the muffler guard isn't covering the hole! Phew

Now I'm just left with the hole problem 

Any best practices for fixing it?

Thinking about just jamming some sort of heat resistant metallic exhaust paste in there.

yay or nay?

[johnny ro]

if it is not crash/scrunch damage then it is rot. I would replace with OEM, I think the whole thing is cheap used.

To repair, your exhaust goop is a good idea and I would rivet a rectangle of aluminum to hold it on place.

Others may suggest cut it off and put on a slip on.

[Toner]

cheers, probably could use a whole new exhaust.
but it's 21 years old and probably not worth the cost.
think I'll stick the paste on and see how long it goes.

just wondering, would it be normal to be spraying gas out of the hole like that?

[chris900f]

just wondering, would it be normal to be spraying gas out of the hole like that?

No!!! fire hazard, don't run the bike like that! If that is gas coming out it means your carbs are overflowing into the engine.

Confirm it is actually gasoline. It looks like milky solution you get from mixing oil and water.

[The Buddha]

It looks like the drainage holes. Yea the can has a tiny hole for getting water out.

Cool.
Buddha.

[Toner]

It looks like the drainage holes. Yea the can has a tiny hole for getting water out.

Cool.
Buddha.

Well here are some pics of the hole. Do your mufflers have holes like this?

[Toner]

the milky look to the substance coming out of the muffler that chris900f mentioned made me think...perhaps the gasket on the header is blown?

[The Buddha]

The muffler has been long trashed in lieu of Yosh trioval ... and of my 17 GS'es I never kept one for more than a month without tossing the can.
That definitely looks like a drain hole. Perfectly stock.
Milky substance isn't nothing blown. Its blowby water vapor mixing with the oil and a bit of carbon and traces of gas. Ignore it and run it, in fact you get the motor nice and hot and you'd stop seeing it milky, it will be too hot to mix and stay a liquid.
Nothing blown. Maybe the filter clump of metal scrubber looking thing in the vent is missing or plugged ... take that off and clean with gas. And dont panic if it looks like mayo in there. Just clean it and run it.

And the symptoms you posted - are water cooled. Not air cooled.

Cool.
Buddha.

[Toner]

cheers buddha. you talking about the wire sponge thing under the breather cover? like this:



it's deffo in there but I'll check it out to see how it looks.

[Toner]

Just to be clear here. the engine is boggy. that's why I noticed the problem.
I had to put the choke on stopped at lights so it wouldn't stall.
Got home and did an inspection and then noticed this problem.
had it running for a while there.
it doesn't stop coming out. the volume only increases when you rev it.
what's coming out is definitely primarily made up of gasoline.

[chris900f]

If it's mostly fuel coming out of the exhaust, it must be sucking raw fuel into the engine. My guess would be that the carb floats are to blame. Probably the best course of action is to pull the carbs, clean the jets and bowls and check the height of the floats and the condition of the two-piece "needle-and-seat" valve (that the floats close when bowls are full). IMO the needle/seat valve is the most likely culprit, they can get stuck or clogged when the bike has been sitting.

The liquid gasoline will wash the oil off of the cylinder walls, and regular combustion will supply enough water to turn the oil/gas mixture to the milky consistency you see coming out of the exhaust. Again, don't run the bike like this, it's a fire hazard AND you could scrape up the cylinder walls. Also, it's probably only one cylinder that's at fault, otherwise it wouldn't run at all.

ps. That close up pic of the hole really does look like a "factory" drain hole. I would ignore it and just get the carbs sorted.

[Toner]

ok thanks. I'll have a look tomorrow.

[Meukowi]

change the oil aswell, probably watery stuff you got there. May aswell change the oil filter while at it