I musta read Z1’s original thread regarding the stock exhaust modification about 10 times before I got the nerve to actually do it. My major concerns were the noise increase and the “ya can’t go back” aspect of the project, but hey with so many rave reviews its gotta be good, right?

Took the plunge this past weekend and have no regrets. IMO the noise increase is minimal and the sound is much better. For those of you who would like to hear my meager attempt to demonstrate the sound difference, check it out:

STOCK EXHAUST
MODIFIED EXHAUST

I have 2 bikes so decided to document the procedure with photos on the 2nd one. The mod is extremely easy so long as everything comes loose. I had some trouble with the screws; tried a screwdriver, then an impact driver, then a Craftsman Screw-out (just ate away more of the head), then finally a Craftsman Power Bolt-out which worked like a charm (quite the handy dandy tool). In fact I went straight to the Bolt-out when I did the second bike...

Before you attempt this mod I highly recommend, err no, I INSIST, you read the thread and accounts originally posted by Z1XT225 et al- he’s the innovator and absolutely deserves the credit here. I just thought I’d do a full description with photos to make it easier for those that follow....
Z1XT225\'s original thread


Tools required:
Drill
Philips head Screwdriver (and/or something to remove a stubborn screw - I suggest a Bolt-out, see above)
Rubber or plastic mallet
Hole saw + extension (I used a 1 ½” but anything less than 2” should do)
Extension magnet
PB Blaster, WD40 or some other penetrating catalyst
Anti seize compound


Access to the screw that holds on the endcap to the exhaust:


Removing the screw with a Bolt-out - drill in reverse:


Spraying around the cap seal with PB Blaster:


A few gentle (or not so gentle) taps...


And out she comes:


continued...

[ July 06, 2006: Message edited by: crash ]

[ July 06, 2006: Message edited by: crash ]

The piece to drill out is about 7 ½” inside the exhaust end:


Hole saw extension end is 7/16 - my drill chuck is 3/8...so jury-rigged it with a 7/16” socket. :rolleyes: Worked ok, but recommend using a drill with a 1/2” chuck...


Drill...


Hole...


And the metal piece:


continued...

Both times I lost the metal piece and had to fish it out with an extension magnet (taped to keep it from catching the side walls). Here with metal shavings from the drilling process:


Start the bike up without the cap in place to blow out excess shavings.

Replace the cap with a new (hex-head) screw with anti-seize compound. The screw on the left shows how much I messed up the head on my first try...


Done!

There are other tips and tricks in the original thread if you get into some difficult situation like not being able to get the dang end cap off. So again I urge you to read Z1’s original thread: Z1XT225\'s original thread

I still have a bit of riding to do to get the full impact of this mod, but my initial impressions are the same as everyone else - wow! Thanks Z1 and all the others before me

Crash,

Very nice job of documentation. I wish I had seen your pictures before I did mine. This will definitely help anyone who is contemplating this mod, and like you said....WOW.

Thanks for the photo "how-to". Just what I need to spur me into action!

BTW - the links to the sound files cause my browser to shut down.

FreeMe - don't know why your browser would crash

If you wanna hear the sound files shoot me an email at kbrame@uplink.net and I'll mail 'em to you.

I will be trying this procedure this weekend and will then share my experience. Without those pic's from crash I would have been lost. I will let all know the out come...

well I also took the plunge and tried this mod!
as per normal the screw was seized and I stripped the head, so I drilled it out and used a self taping bolt with a 10 mm head.
I have not really tried it out yet but we are going on about a 200 + km ride tomorrow so we will see what happens!
I also adjusted my valves with the help of the valve adjusting for dummies post!(funny that was posted just when I was thinking it was time to get them done?)
I also did the carb adjust!(3.5 turns out)
while I had it all apart I cleaned the chain,air filter, and changed the mobile 1 synthetic oil, lubed the cables,kickstand, footpegs, shifter, brake lever,adjusted the chain,and back brake!
it was some day! I managed to get gas in my right eye, dirt in the left eye, cut my hand twice, and tripped over my kids kdx 200.
all in all I did more than what the shop did on the service that cost me $200 canadian!
Thanks too the guys that post all the great information and pictures on this site!
it is greatly appreicated!
Evil69

[ July 08, 2006: Message edited by: evil69 ]

Nice job on documenting this mod Crash. It's nice to see the number of people that have found the same joy that I did in doing this mod.

do you have any idea if it will give a noticable boost in power?