Here is the damage I am seeing on the center exhaust of my new to me 2006 SY250, it is a pyramid shape from the corner of the engine number block. With the tip just puncturing it, I also hear that some weld cracks but I cannot see any signs of that I wonder if there should be any reinforcement of a particular weld when I am getting the puncture taken care of?

and culprit, Red points to corner and I am wondering if the piece of coolant pipe (yellow arrow) placed there is stock or if it maybe was put there in reaction to this issue, I think it may even make it worse by pushing the midpipe onto the corner:

So now the question is how much of that corner should I be taking off and should I do more than just the corner, like Both rear corners and the rear edge. I would assume the entire block is superfluous material but I would rather get some verification first as to what I should be doing in order to have this not occur again or incur more damage from excessive grinding.

Here it is cleaned up a little:

Edited July 30, 201313 yr by j__h

where you at the denbigh mold trial on sunday i saw a scorpa with a blown mid pipe there

Not me, I am in the United States.

Apparently a blown mid pipe is very common on these bikes.

Edited July 30, 201313 yr by j__h

Looks to me like that number boss might serve double duty strengthening the swingarm pivot area.

And anytime you grind on a number boss, you risk the appearance of wrong-doing.

Methinks you'd be much better off shaping the exhaust to keep the problem from happening again.

I will just be rounding the corner a little, would just be good to get confirmation that the number plate is not hollow.

Round that corner right off, I did. It's solid, there's no risk of going through the casing. The rubbery support is Scorpa's way of trying to stop the engine casing poking through the exhaust. Mine looks just like that.

See also:-

http://www.trialscen...ddle-box-crack/

Edited August 2, 201313 yr by bigmike1961

I did some minimal rounding, but I think it should be sufficient just getting rid of that sharp corner.

The weld is fairly ugly due to the oil that could not fully be removed from inside the pipe, but it should work.

I took more off the corner than that.