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Varadero Exhaust Clamp/Gasket defect model 1998-2006
THE PROBLEM
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PLEASE NOTE before reading this section: By changing your bike, adding the modifications as mentioned on this page, you must understand that – if your Motorcycle is still under warranty – this can- and will affect any possible and future warranty claims to the manufacturer. Adding any of the modifications as mentioned on this page or this website in general, is purely the responsibility of the owner of the affected motorcycle.
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The Problem: The exhaust clamp of the XL1000V Varadero can cause problems. First signs of a defect are frequent ‘After-Burners’, ‘banging’ from the exhaust mufflers. The problem is in most cases caused by a defect exhaust clamp, located in the left exhaust system (standing behind the bike). The problem clamp is located left from the rear shock unit, above the rear fork. It is the first clamp after the rear cylinder. The gasket is art. nr. 11 on the picture below:
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The original clamp from Honda (see attached detail pic ture) is expensive and is not a guaranty that the problem is solved. This situation is very similar with the fuel pump issue described on this website!It is a well-known failure; however, not all bikes are affected. There is however a relation with your riding style. It seems that the more ‘sporty’ riders are easier affected as the ‘touring’ riders. Although I normally use the bike for long distance riding under high speeds (German Motorway), my first gasket blowed after 50.000 km. on the MK1. There are recorded failures on the fuel injection models which show that the gasket can blow after app. 20.000 km! |
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The solution for this defect – and a suitable replacement for the over-priced Honda originals! – have been provided by the German Varadero Forum and a Dutch Varadero rider, who already made these modifications. The modification is described below and illustrated with pictures. The Varadero International Team would like to thank Varatro_2003 for his help and his detailed information, including the pictures on this page. Varatro’s real name is well-known by our team.
Location of the defect clamp/Gasket: The defect clamp/gasket is located between the chain and the rear shock unit. It is the first clamp of the rear cylinder. It is not the gasket which is causing the problem, but the clamp. However, the defect clamp can-; and will result in a defect gasket as well! Varatro has changed the original Honda clamp by a Volkswagen clamp (Part Nr. in Germany: 191-253-139). Please notice: this is NOT a 36 mm clamp, but 46,7 mm. Estimated price indication: € 5,- / 7,-. When ordering these parts, be sure to take the original Honda clamp with you, including the mountings! The job: How to replace the clamp: - Remove the left cap and chain protector. Remove the old clamp and bent the new one on the top side of the rear fork around the exhaust pipe (1) - Apply exhaust assembly paste (For example ‘Presto’) on the parts before re-assembling; - Lower the clamp and turn the mounting bolt tight. On the pictures beside you will notice the new clamp in place. |
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