full mod of 07 zx6r stock exhaust

[superx65]

I have seen questions about mods to the stock muffler on a 07 08 zx6r. I have seen some on you tube that look like hack jobs and some that look good. I have completely gutted mine out and removed the butterfly and Painted flat black. It sounds and looks great.
1: I took a die grinder and cut on the outlet side of the weld nearest to the exhaust inlet. Make sure to cut as close and straight to that weld because that means less to almost no prep-work before you weld it back shut and the old weld will give you something thick to weld to.

2: Then take a plasma cutter and cut out all the vertical walls and tubes on the inside.

3: While you have the rear section cut out of the back the butterfly is right there for removal, my screws wouldn't come out so it cut them out as well then welded the hole shut that was left from the screw.

4: This muffler is a two piece outer wall construction you will see when you cut it in half, I took vice grips and clamped the exposed end and tacked them together so when you weld the back section on it grabs it and guarantied that there will not be a rattle from a loose inner wall.

5: Now all that is left is to weld the two sections back together. Be patient and take your time welding it together with about 14 volts, and 185 wire speed. Do about 2 to 3 inches at a time in one spot then move to another spot far away from the last one done to keep from melting through the metal. Be sure before welding it together that all of the left over slag pieces are out, remember that the muffler and pipe angle toward the cat so you don't want any pieces falling down there and making rattling noises. Make sure there is no holes or gaps in your welds because the heat coming out could melt the plastics or your girlfriend's ass.

6: Now that you have done that I would recommend the use of header paint of your choice for the entire muffler. After the welding and plasma cutting heat you run the risk of rusting in those places because you have burned off the glazing that is built into the metal.

7: For those pesky little cables left hanging there, locate the exhaust servo motor and pull the little black clip that goes the length of both cables at the supporting block on the servo and remove the cable very carefully. You have to leave the servo connected to the bike if you don't the little red warning light will come on and mess with the bike.

I will say that I removed all the the walls and pipes and I sounds great, real deep and growling. sounds a lot like a zx10 with moded baffles but not over the top at the high end, in-fact when riding you will hardly know the difference due to the location of the exhaust but every one around you will know. I have no rattles and the flat black on the exhaust looks great. Nothing like a all red and black bike with this ugly silver pipe out the back. With the black paint in now blends in great. From removal from the bike to gutting and reinstall took about 3 hours. Any variation of removing the baffle is up to you most people don't have a plasma cuter. You could use a torch but keep the heat down and away from the outer wall, between the two outer wall pieces that I talked about before is a very thin noise/heat shield in there.

It runs great, but does anyone think that I will have to do anything to the bikes mapping for longevity of the bike. I figure is no different than running a after market exhaust like two brothers because that comes with a butterfly block off plate and is basically a straight pipe.

I would like to hear any praise or criticism you might be able to add:welcome.:

[TMAC]

Pics? I think the only longevity issue might be the smoothness of the motor with a less restrictive exhaust and no valve. If you are worried about it I would get it custom tuned. I want to do essentially the same thing to the 636 except keep the exhaust valve. I need friends with plasma cutters and TIG/MIG welders lol.

[edouble]

I know a guy that has melted his undertail from removing the baffles in a stock 6r exhaust....be careful with this one

[superx65]

Originally Posted by edouble

I know a guy that has melted his undertail from removing the baffles in a stock 6r exhaust....be careful with this one

He must have had a hole left or he did what i've seen on youtube where they have cut the the outlet ports off and left them off and used the cap to hide it.
It should actually run cooler the way I have done it because the exhaust gases will just blow out the back right away instead of traveling back and forth in the can. Also did he maybe remove the uper heat shield on the out side perhaps. But thanks for the help I had already taken that into consideration. If you have any more insight I'm open to anything :donkey2:atriot:

[superx65]

Originally Posted by TMAC

Pics? I think the only longevity issue might be the smoothness of the motor with a less restrictive exhaust and no valve. If you are worried about it I would get it custom tuned. I want to do essentially the same thing to the 636 except keep the exhaust valve. I need friends with plasma cutters and TIG/MIG welders lol.

I can get a pic of the finished product and point out here the cuts and welds were. I decided to do it and just dove in unknowing what to expect on the inside. What do you think about a juice box or a pc3. Do they really work I just started doing this because I didn't want what every one else has, I even am thinking about painting all the fairings white. The cutters and welder are complements of my job I run a heavy duty diesel repair shop. ah the perks of being the boss lol. Thanks for the great advice dude, I think that I might actually do a video on youtube explaining and pointing out the key points on this mod.

[edouble]

Originally Posted by superx65

He must have had a hole left or he did what i've seen on youtube where they have cut the the outlet ports off and left them off and used the cap to hide it.
It should actually run cooler the way I have done it because the exhaust gases will just blow out the back right away instead of traveling back and forth in the can. Also did he maybe remove the uper heat shield on the out side perhaps. But thanks for the help I had already taken that into consideration. If you have any more insight I'm open to anything :donkey2:atriot:

Sorry but I dont have any more info on this mod or what he did.

[superx65]

Originally Posted by edouble

Sorry but I dont have any more info on this mod or what he did.

That's cool, trust me any info anyone has I'm very open to it.

[edouble]

My buddy just messaged me on myspace this is what he said

"he had the undertail exhuast..right under the seat..he removed the baffles and didnt put anything back on just let the plastic there on the end of the tail so it got burnt..there is a piece that goes in the plastic i guess or he was going to put something there.. "

[ZX-10R_Sinner]

If anyone wants the muffler off of an 08, less than 1000 miles on it, I have one laying in the garage from a buddy's bike. This sounds like a cool mod so just throwing this out there.

[superx65]

Just for everyone's information I took the bike out today for a long ride against my brother inlaws zx10 for the first time since the exhaust mod. It was phenomenal It was right there all the time never more than about 15 feet behind where as before even with the jumper mod he would just pull away with no problems. Exhaust sounds beyond great runs its a## off. So for anyone with the idea of doing this mod it is totally worth it. again I will try and put the mod on you tube for anyone wanting to do this right. I have seen and heard of really bad ways of doing this and seen some hack jobs on you tube. At 400 to 600 hundred dollars a muffler and only one shot at doing it correctly read the write up on it at the top and please take your time.:helmet: