So, the SECOND broken rear header!

80shilling said:

Just a heads up. My bike just had the rear header snap at the flange AGAIN! Ducati North America denied a warranty claim on it, stating that because I have a non Ducati authorized part on it (the Termignoni front exit slipon) they were denying the claim.

I pointed out that for 30 years, Termignoni WAS the only authorized Ducati exhaust partner, but they didn't care. Under the Magnusen-Moss act, I could go after them, but at the moment, I have way too much going on in my life to chase after them for $800-$1,200.

I always modify my bikes and know going into it that on occasion I am going to run into something like this, but it's disappointing and more to the point, the rear header has now failed TWICE in the identical place. I will be putting the stock mufflers back on, to see if the problem happens again.

After only a little over 10,000 miles on this bike, having the rear header fail twice is giving me some concern quite frankly.

We shall see if the issue re-occurs with the stock muffler setup. In the meantime, I am waiting for a reply from Termignoni Italy to see if THEY are aware that Ducati is blaming their product for this issue.

Click to expand...

That is such ......... That is nothing but a chickenshit cop-out on Ducati's part. They know that damn slip-on exhaust didnt cause the header to break...twice.

I was just about to mention the Magnusen-Moss Act as i was reading your post because i think youd have a good case, but then saw you already considered it.

I hate it when companies will look for a reason NOT to cover something, when common damn sense tells them it had nothing to do with it.

I had similar deal Denied Warrany, I have the SSTK long headers as you know they are listed in Ducati accessories catalog hence officially approved. Warning the long front header curves around under the starter motor to the LH side extremely close to the starter relay and Pos battery cables, sure enough last summer going too slow for too long heat from the pipe melted insulation causing a short killing the bike, luckily it didn't continue to short out, ended up frying the chipped ignition key switch, Ducati denied warranty because they didn't install the headers even though it was installed exactly as per instructions, all these companies are the same hence I hold very little for there warranty and take everything on myself, plus the fact that there's probably only a few decent Ducati Mech in the country the vast majority I wouldn't give them a lawn mower to repair such is the current Parts Changing World we live in very few understand engineering principles

Footnote :- after getting bike back with new ignition, cables, starter replay, I immediately relocated relay & rerouted Pos' battery cables, insulated starter body & cables, otherwise the same scenario would repeat its self.

I personally think that usage temperatures don't mean ..... Exhaust gasses are close to 900 degrees Celcius, manifold hardly cares whether outside temperature is 5 or 35 degrees.

But OEM manifold is long. Akras and Termis first joint is after 10cm. And actually it was like that on 998/999/1x98 exhausts for the rear cylinder. I think it is the vibration killing the manifold. It is false design, but not so many cases that Ducati (yet) has to admit it. Why do some break and the others not. Maybe the distances driven at some high vibration revs / frequency?

Thinking about warranty, more interesting are these Rapidbike/PCV/Tuneboy etc modules. In most cars the warranty is out of the window whenever some cheat boxis installed or engine management is touched. I wonder when motorcycle manufacturers follow the car industry.

Raaseri said:

I personally think that usage temperatures don't mean ..... Exhaust gasses are close to 900 degrees Celcius, manifold hardly cares whether outside temperature is 5 or 35 degrees.

But OEM manifold is long. Akras and Termis first joint is after 10cm. And actually it was like that on 998/999/1x98 exhausts for the rear cylinder. I think it is the vibration killing the manifold. It is false design, but not so many cases that Ducati (yet) has to admit it. Why do some break and the others not. Maybe the distances driven at some high vibration revs / frequency?

Thinking about warranty, more interesting are these Rapidbike/PCV/Tuneboy etc modules. In most cars the warranty is out of the window whenever some cheat boxis installed or engine management is touched. I wonder when motorcycle manufacturers follow the car industry.

Click to expand...

I am beginning to think that you are right; I don't think it's a temperature issue, I think it's wear and tear, created by my daily commute and the major amount of broken-up roads I am riding on.

Time will tell, once I get the bike back with the stock muffler on it.

Rear down pipe failed in exactly the same place a few years back on my old 999R

There is obviously a stress point there. Maybe from the weight of the mufflers pulling down on it?

Slow said:

There is obviously a stress point there. Maybe from the weight of the mufflers pulling down on it?

Click to expand...

I don't think so. The mufflers are bolted to the crank case, and the pipes are joined by slip joints and springs

I'll look into it. But make sure there are no nicks scratches or rough welds around there. if the welds are rough, smooth them out. Try to eliminate stress risers.

I'm going with rough road and possibly not enough flex in the exhaust. See if you can add a rubber gromet anywhere and make sure the headers and mufflers are properly supported. I thought the 1199 was pretty well done last time I looked closely at mine.

Ducati already warrantied 1. The don't have to warranty another whne theres a termi slip on involved. Mag Moss doesn't apply. It's entirely possible that the Termi parts are tugging on the exhaust during hard bumps.

And if the part isn't installed by a Ducati tech, there is obviously a decent excuse to deny warranty there as well. It's very easy to F up a Panigale exhaust.

It's funny that Ialians or Germans warranty anything at all, Can't count on warranty with any brand from there. But this stuff ain't nothing compared to Mitsubishi. They'll deny warranty on a $300,000 engine for little or no reason at all. (fuel lines were a foot too long to the fuel tank, so that caused the cam to fall apart and grenade a dozen cylinders, BS)

Lol my last car was a lancer evolution X. Mitsubishi definitely sucks donkey balls when it comes to warranties. Your AYC pump failed? We can't warranty it because you have an aftermarket rear view mirror.

Whattt??

double0 said:

Lol my last car was a lancer evolution X. Mitsubishi definitely sucks donkey balls when it comes to warranties. Your AYC pump failed? We can't warranty it because you have an aftermarket rear view mirror.

Whattt??

Click to expand...

Ha, this happened to me with my Evo VIII. Mitsubishi would rather lose customers for life than pay $400 to fix one of their brand new cars under warranty. Never again!

80shilling said:

I am beginning to think that you are right; I don't think it's a temperature issue, I think it's wear and tear, created by my daily commute and the major amount of broken-up roads I am riding on.

Time will tell, once I get the bike back with the stock muffler on it.

Click to expand...

If my experience means anything, this has nothing to do with broken up roads. Your wheels would be destroyed long before your exhaust would fail. My vote still goes for a high frequency resonance.

Sorry to hear but not the first time I've seen Termi's pipes crack. I hate to say it but Termignoni exhaust are low quality.

I've an extra Termi flange adapter D155Y for sale for the front exit Termi Carbon.

RRnold said:

Sorry to hear but not the first time I've seen Termi's pipes crack. I hate to say it but Termignoni exhaust are low quality.

Click to expand...

I might be wrong but I think it's the stock headers that are cracking when running the Termi slips

My local dealer is hosting the Ducati Experience this weekend... evidently, they show you a broken down demo bike and tell you that the repair isn't covered under the warranty.

sounds like engineering issue. I will note that after install and several full heat cycles the exhaust fasteners should be re-torqued to ensure even fastening. This is something I read on an Akrapovich manual.

I have an identical exhaust setup as 80shilling, except that I've wrapped the rear header. No problems....yet.

80shilling, if you do go full Termi headers, please post up the part number. I've been thinking of doing it, but can never figure out which header set was designed to be used with those slip-ons.

80shilling said:

I am beginning to think that you are right; I don't think it's a temperature issue, I think it's wear and tear, created by my daily commute and the major amount of broken-up roads I am riding on.

Click to expand...

But even so, it still isnt your fault. It is a design flaw. Hundreds of thousands of bikes worldwide have been ridden for tens of thousands of miles on all kind of ...... roads, even offroad, without exhaust headers breaking in half.

There is more to it than Ducati just not wanting to spend the money on fixing your bike. It is also because they do not want to admit fault. Several people just on this one forum have had exhaust headers crack/break, imagine how many have had the same issue worldwide (that just dont frequent forums).

If Ducati starts fixing these headers, then it means they are admitting there is a fault...which means they could/would be forced to issue a recall...which could ultimately cost them millions, not to mention further tarnish the bad name Ducati already has when it comes to quality and reliability.

So to avoid a major shitstorm, it is MUCH easier, safer and less expensive for them to just simply tell individual owners to .... off.

Bare in mind none of these aftermarket exhausts fit perfectly, so problem could we'll be too much stress, the system needs to be fully installed before tightening the mounts so the system can distribute any stresses across the whole system rather than too much tension on 1 slip joint

Another rear header failure, around the 5,000 mile mark. Stock headers again, Akra slips - same as Shilling spends most of its time commuting.