450 EXC header is it worth it?

Hey guys i have a ktm 450 exc 2004 model and i dinged in the header pipe pritty badly. I was wondering if it is worth cutting that section out and welding another piece in there? or should i just fork out the $358.70?

Thanks for reading,

By former Kxf rider.:thumbsup: :thumbsup:

PS: Is it stainless or titanium? Thanks

Have a go at freezing it out.My 520 had a big ding in it when I bought it and I froze the dent out near perfect.There is a link on the forum here somewhere about how to do it but basically- remove header, fill with water to cover dent(leave both ends open) freeze it but as the dent starts to come out un freeze it and then freeze it again.Other wise you may end up splitting your pipe(I did).But I left it in over night and it froze to solid.It split along the seam in the pipe but have migged it up ok.

You have nothing to loose.

The dent




The split


The near finished repair job


I have the same exact problem, I will be going to midas and checking the dumpster in the back, grab a pipe that matches the bend close and cut out the dent as you stated and put over a piece and weld it. Mine is smashed so deep it's actually concave.

I just finished welding a two stoke pipe last night, they are much thinner and I did it with a tig welder at 42amps 3/32 torch, the 4 stroke pipe should be a breeze.

Do not buy a new pipe, if you cant weld then buy a parted out pipe off KTMtalk for 40-80 $$$ or cut the piece out and have midas weld it for you.

They will work on just about anything you ask, just no warranty.

if your is dented and not concave as mine the freezing trick might work, never tried that.

Replace the stocker with an H-t racing head pipe, its cheaper, fits better and it will run better too. FYI many pipe repair companies can blow those dents out pretty easy.


2004 pipe is a little different but good example of how a cheap pipe can be had.

I repaired my heavily dented pipe by drilling a hole big enough to fit a rounded punch through (about 3/8 inch) on the side opposite the dent.Then I heated the dented side and beat out the dent with the punch through the hole. I then brazed up the 3/8 hole. I tried brazing with coated brass brazing rod at first but it did'nt work very well. I had some 15% silver brazing rod that is used for brazing copper pipe laying around and tried it and it worked really well. You can get it from a welding supply store. You can tell the pipe was dented but it will get by until I get a HT pipe.

I bought a new stocker from ktm-parts.com. If you register with them (no cost) you get a 10% discount on everything you order. I paid $171 for the replmt. It is a nickel plated steel that will turn color with time/heat. Good stuff. Be sure to get the replmt spring kit for a few more bananas.

Saw an '05 on KTMTalk tonight for $50 or $60.

Thanks guys for all your help.

I just cut out the dinged up piece and panel beated it. Then I welded the piece back in then grinded it back. It looks alright. :thumbsup:

Thanks again KTM rider.

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now

  • Similar Content

    • By Ponch
      I have a 2007 450 EXC that I recently installed a new clutch slave cylinder on. Per the 2007 KTM service manual it clearly states that the clutch needs to be filled with hydraulic oil, which I did (magura blood). That was yesterday. I went out to double check the level today and when I removed the cover, the rubber seal was all contorted and out of shape. I then looked at the cover and it's a Brembo clutch and says "DOT 4 brake fluid only".
      I flushed the line and the master cylinder about 7 times with DOT 4 brake fluid and there was no sign of the magura blood left in the system. My question is: other than the rubber boot on the master cylinder, what damage might have been done by putting in the hydraulic oil? It was in for about 24 hours.
      Thanks in advance for any advice!
    • By pumpernickelBrad
      Hi Folks!

      Sorry if there are a bunch of threads already but I used the site's search function and didn't find anything so far...

      I just found a decent deal on a '14 350 EXC-F with 11k km (unknown hours). Has a few goodies including skid plate, hand guards and it's for sale for about $2k CAD less than a '16 with 6k km on it.
      The bike is in showroom condition (appearance) with no indication it has been offroad at all.

      What would be the gotchas that would make this deal realistic? I'm coming from a WR250R where the engine lasts forever, is 11k street kms high for these bikes? 
      Are there any big defects in the '14s that I haven't dug up yet?
      With no service records what things should be done, checked, etc?
    • By Brannnt
      I purchased an '06 525 EXC some time ago, and recently pulled the motor out of the frame to address some other issues. When I removed the clutch slave cylinder, I noticed an issue the previous owner neglected to tell me about during the purchase.
      It appears that at some point, the chain broke and damaged the engine case near the clutch slave cylinder (see pics, please). I have noticed that the clutch does not fully disengage (bike lurches a bit going into gear, neutral is hard to find... its worse when engine is cold) ... I did not notice any leaks around this area (mineral oil or engine oil) before or during disassembly. 
      The previous owner (or someone) repaired it with some sort of epoxy.
      Without doing my due diligence (checking clutch fluid level, bleeding) I hesitate to state that this is the cause of my clutch disengagement issue ... but pardon my ignorance here and help me out: How bad is this?  Am I looking at replacing my engine case here or is the previous owner's jerry rig good enough?

    • By Black Sox
      Just bought a new 2017 350 excf ,will be doing 98% off road ,ordered skid plate bark busters ,
      my ? Is what's the best easiest way to eliminate rear fender light assembly.I still would like to have a break light.
      xcf fender will fit so dealer says,under $50.00 👍But xcf brake light $125.00 .👎What's the best economical way of doing this?
    • By JNV
      Hi friends from Spain.
      Mi new KTM