Standard Exhaust Shinanigans

[MY45]

Ok so ive been over in the shed cutting away at my exhaust, so i thought id better show you what ive been up to.

I read lots of posts warning not to cut it up but i just couldnt help it.

So 1st up i cut the zip ties that hold the exhaust sensor wires (they run along the right hand side and then across the top of the horizontal piston) and then unplug the sensor wire.
Now that is disconnected you can undo and drop the rest of the exhaust and unscrew the sensor from the cat pipe.

When you are pulling the exhaust apart you can remove the cables that operate the exhaust flap (in the pipe before the mufflers). Then you can leave the little electric motor plugged in and wont have engine light problems.

Emptying the cat......now this is a bit of a bitch. you will need to cut just next to the weld around the exhaust side with your hacksaw. The only way i could get the cat material out was to use an oxy and just melt it out. It is made up of tightly packed "wavie" metal and it took me about 15 min with the oxy.

Then i welded it back together and checked if it would all fit back up.

Next it was time to give the mufflers a bit of lovin. I removed them from the bike and marked about 20mm back from the aluminum end caps. Again cutting with a hacksaw i cut the end cap off. Once that is done you will notice 3 holes on the engine side (1 right through and 2 blocked by a plate) and just the single hole in the end cap.


I then drilled into the plate behind the 2 holes that were blocked ( i used a pilot then about a 20mm drill).



Next was to open up the end cap. I used a hole saw of the correct size to remove the inner pipe, drilling from the outside in.




Next is to line up the ends with the mufflers and weld them back together.







Next i removed the aluminum end caps by drilling the tops off the pop rivets then hitting them through with a punch. So that you re-paint the mufflers as all your welds will rust. I will paint all the pipes from the cat up black (make sure it is with high temp paint or it will just melt off)

Now its time to fit it all back up and dry the paint as per instructions.


I haven't got mine painted up yet but will try and get some pics of it all done tomorrow.

Adam

[AXE]

Great work! I know that takes some time and it would be great to see if you are rewarded with good performance gains and sound quality.

Let us know what happens. Do you have access to a dyno to see what the numbers are after the mods?

Out!

[GEE-BEE]

Great Work !

For 155.00 you can have the whole system ceramic coated satin Black
Gee-Bee

[speedfreak]

I thought about doing basically the same thing but welding the crossover pipe shut and making it a single muffler. Then somehow seal the other endcap and make it removeable. Mount them up to look like the stock dual pipes but only one is a silencer and the other is a storage space. Still have the dual pipe look but the single pipe sound and performance and a little storage without an ugly tank/tail bag.

[HYPER01]

Just a suggestion.
If you have the cash................buy the Termi system.
Not only you will have the new Electronic box, but it look a lot better.

[sick50ford]

Originally Posted by MY45

I haven't got mine painted up yet but will try and get some pics of it all done tomorrow.

Adam

i think adam welded up this to. very sad

[snow]

great work for the bucks

[MY45]

Originally Posted by sick50ford

i think adam welded up this to. very sad

Come on its not that bad. No one even noticed when it was all painted up, and for the price...$0 the sound was great. I could of taken it to a boiler maker but i figured that the money would be better spent on a full zard system that it has been wearing since august

[krill]

Originally Posted by HYPER01

Just a suggestion.
If you have the cash................buy the Termi system.
Not only you will have the new Electronic box, but it look a lot better.

Am I the only one that likes the look of the standard exhaust (except the cat bit) and thinks the Termi especially the single one is pig ugly

[kingsnake1650]

Originally Posted by krill

Am I the only one that likes the look of the standard exhaust (except the cat bit) and thinks the Termi especially the single one is pig ugly

Im with you krill! the only thing that looks worse than the termi single pipe is the price tag they hang on it!
I cored my stock pipes gutted the cat, anf had the hole system powdercoated black. Add fat duc, and powercommander. Total price less than $500.