Free 5 minute exhaust mod

[moorenycc]

I performed a free 5 minute exhaust mod on my FZ6R today using 2 flat head screw drivers and a hammer. This mod retains a stock exhaust appearance. Here is how I accomplished it:

1) I took a long, thin flat head screw driver and placed it into the exhaust outlet as for in as it would go in. When the screw driver bottomed out and would no go in any further, I hammered a hole/slit through the internal baffle using the screw driver. I then spun the flat head screw driver 90 degrees and hammered another hole/slit in the internal baffle (you can see what you are doing by using a small flashlight). Now at this point, if you shine a flashlight inside the exhaust outlet, you'll see a small "X" shaped hole in the internal baffle from punching the screw driver through it.

2) Now take a much larger flat head screw driver and do the same thing, making the internal hole bigger. Begin rounding out the hole on the inside. I continued pounding and working the metal ultimately until I had a smooth, internal hole about the size of a quarter.

The sound is fantastic (but not too loud) and is comparable in sound to the other popular exhaust mod done on this forum. I have ridden the bike slow, fast, hard, and I have no popping, back firing, rattling, etc. It sounds great!

For an even louder sound than mine, all you would need to do would be to continue working the hole larger and larger on the inside (maybe the size of a silver dollar)- or even slightly larger until you reach the desired sound.

Best of all, it still looks 100% stock. It is even hard to tell I did something when shining I flashlight into the exhaust outlet!

I'll try to post some pictures soon.

 

[JSP]

I was wondering if we could reach the baffle... A lot of people do this on mufflers. We had a bunch do it to the Honda Rebels and it made them sound really nice. Can you get a sound clip up of it? I may just do this as you wouldnt ever really notice anything was done.

 

[2w05thletes]

+1 on the photo and video clip. Sounds like a fantastic idea.

 

[CDN6R]

This is so simple,,,why did not one of us think of this before? :thumbup: How about trying a long drill bit and making a hole

 

[dart1963]

I believe this has been talked about, it is also an irreversible mod, mess it up, and you're out an exhaust.
Also, won't this open up the inside for faster corrosion? Not sure the design of the muffler, but I know when it rains, I get a little bit of water in their, just wonder what this will do.

 

[Blue-Sun]

I believe this has been talked about, it is also an irreversible mod, mess it up, and you're out an exhaust.
Also, won't this open up the inside for faster corrosion? Not sure the design of the muffler, but I know when it rains, I get a little bit of water in their, just wonder what this will do.

Kind of reminds me of a kid in high school that borrowed his father's station wagon and punched holes in the muffler with a hammer and nail, because he wanted the car to be "cooler" for a date. It was louder, but the father was so pi$$ed that he had to replace the muffler on his car for fear of getting a repair ticket. Maybe you can "cool" up an old Nomad, but this was no Nomad.

 

[moorenycc]

when I was doing this mod, I tried first using a drill bit but I couldn't find one long enough. So I just used a long screw driver. I kind of like the idea of not having any drill shavings possibly falling in the muffler also. As far as water getting inside and corroding the metal around the hole- I think it is unlikely but I suppose it is possible. The inner hole is quite far inside (I'm guessing close to 12 inches). Overall I think it is a easy and satisfying mod. The bike still looks 100% stock. Just remember that it is irreversible. Also, still working on pics/video.

 

[Roaddawg]

Is it a baffle that your punching through? I thought, according to those that have hole drilled theirs said it was a tube that bent downward once inside.

 

[ME_with_a_B]

Heh... this sounds like a mod even I could do unsupervised... can't wait to see pics!!

 

[Spunky99]

OMG......

You have me doing another mod...???

OK..I can't help myself...I just cant...........

 

[redwing-2001]

ok, all you mechanics out there. Will this mod affect the back pressure enough to do any damage to the top end and will it mess up or require any new mapping? I don't know, that's why I'm asking.

 

[CDN6R]

I am not a mechanic,but I can't see this mod causing any issues with the EFI or loss of back pressure. I am quite sure that a aftermarket exhaust will be louder and people run lots of different aftermarket exhausts on these bikes (FZ6R/XJ6N/XJ6 Diversion/XJ6 Diversion F) with really no issues.

 

[Heineken]

Heh... this sounds like a mod even I could do unsupervised... can't wait to see pics!!

Hmmm, want to do that Sunday after the breakfast/ride deal?) I still got 160 of those skinless sausages )))

 

[JSP]

Hmm... I'm not sure how you did what you did. I just went out and took a flashlight to the exhaust. I see no baffles in there. The pipe goes back and then bends downward and to the left it seems. Were you actually busting through the exhaust tube? There was no way to reach the baffles. The pipe just curves.

 

[Roaddawg]

Hmm... I'm not sure how you did what you did. I just went out and took a flashlight to the exhaust. I see no baffles in there. The pipe goes back and then bends downward and to the left it seems. Were you actually busting through the exhaust tube? There was no way to reach the baffles. The pipe just curves.

That's excatley what I thought as well. I'm thinking he just put a hole through the tube, maybe bypassing the baffles?? Anyone have a design diagram of the exhaust box?

 

[Spunky99]

I put a screwdriver up the kazuu and poped a hole in I don't know what...felt like a redneck the whole time. Got out the big flathead and turned it so the hole was about 3/8" diameter. Sounded the same to me, maybe a little more low note but not really any louder. Bike ran the same too.

 

[CDN6R]

Wasn't there someone who wrote on this forum about splitting the exhaust "box",gutting the baffles and rewelding it back together? I am sure I read that mod somewhere or maybe they were just talking about doing it!

 

[JSP]

I found this post, but I dont see he ever posted pics...

http://www.600cc.org/forum/f91/my-exhuast-mod-19043/

 

[dart1963]

hey guys and gals.. im new here and was asked to explain my mod.
Im sorry i didnt take pics ( insert .. this thread is worthless without pics here)

Yeah, and I doubt we will get any... that's not something you'd do again just to get pics.

 

[moorenycc]

You are actually punching through a bend in the inner exhaust pipe as it bends and exits the muffler. The inner pipe makes up part of the inner baffle system. When I was doing this mod, I didn't start hearing a notable sound difference until the hole was about the size of a quarter. As the hole got bigger I was able to put a small metal pipe (used for plumbing) and punch the hole smooth and about the size of a silver dollar (I'm guessing). I have noticed a big difference in sound- without any popping/back firing, but it is not super loud. So those who want really loud will have to go with aftermarket exhaust.