Swapping Exhaust Advice

**Mick DB1** · #1 22 Jan 2008

Hey up
I am still using the original exhaust on my XT600. The silencer is corroding bad and the clamp has rotted through. I have sorted it all out now but next time its off its off for good. I know some of you have purchased new systems but I would like to fit a second hand remus or micron off a donor bike to save me dosh for other things. My question is then - Has anyone fitted / grafted a donor silencer to the original downpipe, and if you have which/what bike did it come off. I have a tig welder in the shed so a Stainless steel slip on type to SS pipework would probably be the best option
Cheers Mick

**Ilpoj** · #2 22 Jan 2008

Im currently trying to get a muffler from kawasaki z750 to fit to my XT600.

**Martynbiker** · #3 22 Jan 2008

Quote:

Originally Posted by Mick DB1

Hey up
I have a tig welder in the shed so a Stainless steel slip on type to SS pipework would probably be the best option
Cheers Mick

Well Mick, If you have a Tig, then you Obviously know how to use it!
My suggestion is to take your old exhaust and cut it up and copy it in Stainless... Maybe making it just a 'teensy weensy' bit more free flowing?
if you make the end cap removeable by say 3 allen bolts you can pack the can with Glassfibre wadding and hey presto matey! Custom Pipe cheap as chips!
Pipe of correct diameter can be bought from a stockholders or engineers reasonableish I would say at the outside 50 quid to get you what you need and you would have a pipe that would outlast your bike.

Martyn

**bruken** · #4 23 Jan 2008

I tried a Micron

took it off

too bloody noisy by half

gave me one hell of a headache

told every rozzer within two miles to expect my immenent arrival so to get ready with the ticket book 'cause I'm obviously breaking the law

every poor SOB who never had a girlfriend used to give me a thumbs up at the racket

that was the final straw. Bought be a good cheap and quiet Sito number. Does the trick and can ride in peace.

Seriously tho. A loud exhaust on a thumper will get to you on a long ride and you'll be surprised at how taxing it can be.

**Martynbiker** · #5 23 Jan 2008

Quote:

Originally Posted by bruken

A loud exhaust on a thumper will get to you on a long ride and you'll be surprised at how taxing it can be.

if you copy the orig design...... but make the holes lets say 8mm instead of 7mm it will flow a lot more gas faster.... bearing in mind that you are also able to pack the wadding tighter or looser to muffle the sound too....

Martyn

**bruken** · #6 24 Jan 2008

I have an inverter. To scratch make an exhaust with all the correct bends, air flow, volume etc would be an undertaking of quite conciderable order with very little chance of sattisfactory results. In fact an inverter would be the very least of your requirements. (I build mufflers for my 50 - 150 cc model aircraft and PIA you would not believe to get it right within the 87dB allowed. And those are movable tuned pipes on strokers. You wont be so lucky.

(*****)

**Ilpoj** · #7 24 Jan 2008

Quote:

Originally Posted by Ilpoj

Im currently trying to get a muffler from kawasaki z750 to fit to my XT600.

If you wanna see how its going... Here's a pic...

**zap2504** · #8 24 Jan 2008

Quote:

Originally Posted by Ilpoj

If you wanna see how its going... Here's a pic...

Looks very good! What do you have in mind to fill in the frame strut area (where the OEM muffler used to provide that function)?

**jimmy46** · #9 24 Jan 2008

I dont wish to rain on your parade, but be aware if you wish to fit hard panniers with their associated brackets it is a little tight at the rear. I have just had to remove my Micron after market exhaust since it was too big to go inside the touratech pannier brackets, the OE is just that little bit smaller dia...Then agian maybe your not fitting panniers so all the above is of no interest...

Regards Jimmy

**cyberzar** · #10 24 Jan 2008

My advice is for leovince X3, it's road legal in EU, not too much noise, and if you can weld you can hunt on ebay an odd second hand version for some strange bike (cheaper), then do the first part (initial tube) of the exhaust by yourself. I'm doing this for my TT350.

No problem with panniers, I got the Hepco installed, and the isssue with the original exhaust being part of the frame can be quickly corrected doing a curved bar to screwed in this place. Marving for example sell this bar, but it's done for their exhaust so i'm not sure if it fits with others.

**Ilpoj** · #11 24 Jan 2008

Thanks for the advice jimmy46, but I wasnt going to install any luggage panniers in the near future at least.

And zap2504 thanks for the compliment, not yet sure what kind of pieces I need to make to make it all fit well. And Im going away for the weekend so cant do anything. :(

**Ilpoj** · #12 30 Jan 2008

Here's a pic of how I got the silencer to fit right...
The sound isnt much louder than in the original, and its softer in a way.

**Martynbiker** · #13 30 Jan 2008

Quote:

Originally Posted by Ilpoj

Here's a pic of how I got the silencer to fit right...
The sound isnt much louder than in the original, and its softer in a way.

Wat about the frame strut?

**Ilpoj** · #14 31 Jan 2008

I just put a bolt through it for now.

**Martynbiker** · #15 1 Feb 2008

Quote:

Originally Posted by Ilpoj

I just put a bolt through it for now.

Didnt the Exhaust make up part of the strengthening of the subframe on that model?
Putting a bolt through that hole wont make the subframe any stronger.... I think you need to fabricate a strut to go to the mounts from the triangular bracket, for safetys sake at least.
Then again I could be wrong?

Martyn