WELL DIDN'T TAKE LONG TO FEEL THE NEED TO MOD THE BIKE A BIT

HAVING LOOKED AT ALL THE AFTER MARKET CANS I JUST COULD NOT JUSTIFY THE COST OF THESE,

 SO OPTED FOR THE RACE BAFFLE CONVERSION

KITS ARE AVAILABLE ON EBAY AND FROM A&R IN THE USA

HERE IS A WALK THROUGH OF HOW I DID IT AS ALTHOUGH I READ UP

ON THE PROCESS THERE WERE SOME GAPS IN THE INFO

STD EXHAUST NOTE

OK SO WE START WITH THE BODYWORK REMOVAL

REMOVE THE SEAT AND PILLION SEAT AND IN THIS CASE THE GRAB RAIL

YOU THEN NEED TO UNHOOK THE SEAT LOCK AND REAR COWL WILL COME OFF

REMOVE THE EXHAUST HANGER COVERS

REMOVE THE HEAT SHIELD

REMOVE CLAMP BOLTS

REMOVE TOP BOLTS SUPPORT THE EXHAUST AT THIS POINT

YOU WILL NEED TO WIGGLE AND TWIST TO GET THE EXHAUST OFF, ALSO WATCH THE GASKET

ON THE Y PIECE AS THE TINY WIRES WILL PEARCE SKIN AND CAN BE PAINFULL

EVER WONDERED WOT IT SOUNDS LIKE WITH NO CANS?

EXHAUSTS OFF AND LAID OUT

USING A 5.5mm TWIST DRILL I DRILLED THE RIVET HEADS - TIP DON'T DRILL THROUGH

DRILL JUST ENOUGH AND USE A PUNCH TO KNOCK THE RIVET THROUGH

THE NEXT BIT SOLVES THE PROBLEM OF THE SPOT WELDS - IN MOST CASES THE SPOT WELDS

NEED TO BE DRILLED OUT - IT'S A RIGHT PAIN SO I DID IT MY WAY

USING ELECTRICAL TAPE I RINGED THE EXHAUST, THIS WILL SERVE AS A GUIDE.

THEN WITH A NICE SHARP BLADE IN MY HACKSAW I CUT ALL THE WAY ROUND

YOU WILL NEED TO DO THE SAME TO THE BAFFLE  (ON A&R) TO CORRECT THE BAFFLE

LENGTH  

IN THE PICTURE YOU WILL SEE I USED TWO WRAPS OF TAPE THIS IS BECAUSE I WANTED

TO SHORTEN MY EXHAUST, FOR NORMAL APPLICATION AS ABOVE ONE WRAP

YOU CAN NOW PULL THE CORE OUT COMPLETE

CUT THE WADDING DOWN IN A VERTICAL LINE CUTS EASY WITH A STANLEY KNIFE

AND CUT AROUND THE TOP AS YOU WILL BE REUSING THIS MATERIAL

CUT TO SIZE AND RE-WRAP THE WADDING AROUND THE NEW BAFFLE MAKING

SURE THE COPPERIZED SIDE (INNER WADDING) IS AGAINST THE BAFFLE

HOLD WITH TAPE (THIS WILL BURN OFF LATER)

TRIAL FIT INTO EXHAUST

TRIAL FIT OF CAP TO ENSURE ALL FITS TOGETHER

OK WORD OF WARNING HERE AGAIN AS YOU CAN SEE I WAS WEARING SHORTS

BAD MOVE THE ASBESTOS MADE ME ITCH LIKE MAD ALL NIGHT, AND THE BITS OF

WIRE WOOL GOT IN ME SHOES, SO DONT WERE SHORTS

OK PACK THE WIRE WOOL INTO THE EXHAUSTS PACKING DOWN FIRMLY, I USED

A HAMMER HANDLE

AS YOU GET NEAR TO THE TOP YOU NEED TO SHAPE IT UP TO A CONE

REPLACE THE CAP AND I DRILL PILOT HOLES FIRST THEN THE 5mm HOLE FOR THE RIVET

INSERT RIVETS AND SQUEEZE SLOWLY TO ALLOW FACES TO PULL TOGETHER

AND THERE YOU GO APPLY TO SECOND EXHAUST AND REFIT - MAKE SURE YOU USE

COPPERSLIP OR SUITABLE GREASE ON THE EXHAUST CLAMP BOLTS TO EASE REMOVAL

 IN THE FUTURE

AT THIS POINT I ALSO CHANGED THE Y PIECE FOR A DE-CATED ACKRO ONE,

TRICK HERE WHEN REASSEMBLY IS TO HAVE EVERY THING LOOSE SO IT CAN FIND IT'S

OWN POSITION CLAMPING UP THE Y PIECE FIRST MADE IT IMPOSSIBLE FOR ME TO

GET THE EXHAUSTS ON..

END RESULT

OK BUTT DYNO SAYS MASSIVE INCREASE IN MID RANGE AND THE SOUND IS EXCELLENT

MODS DONE ALTOGETHER WERE - K&N FILTER, DECAT Y PIPE AKROPOVIC,

RACE BAFFLES AS ABOVE, POWER COMMANDER, AND BRAVERMAN MAP

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