Any engineers out there??

[maraach]

Hey guys,

Long story short, i have a full Yoshi RS-3 system on my zx9r, and its great. However, when i fire the bike up on weekend mornings my neighbors must want to kill me.

I found out recently you can buy low volume inserts for the exhaust, and went ahead and purchased one. What i didn't realise is that i don't have the two threaded screw holes or mounting spots for the insert to screw into (please see below link for visuals of what i mean).

http://cbrworld.net/forums/thread/263711.aspx

Basically, a lot of time, money and effort has been spent setting my bike up to run great as it is. I realise that when i put a low volume insert in, it wont run as well as the jetting will be off. However i would like the ability to reduce the volume when necessary. The low volume insert would have been perfect, but alas, i cant really use it the way it was designed.

I was just wondering if anyone could think of anyway i could use it, or get something similar made up for my exhaust? I would like it to be relatively easily removable (10 - 15 min job). I can buy a new end-cap which is correct, but its a 2 month lead time, and i have to drill out all the old rivit's. So would rather think of a easier solution if possible.

If anyone has any idea's please let me know.

[oldmanmike]

How does yours differ from setup in the link you provided ??

Pictures please...

If its only the fact that the 2 threaded holes are missing, thats 10 minutes with a drill and tap..

[Gazza]

if the flange still fits in the reecesed area of your original exaust
all you need to do is put it in position spot the 2 holes from the flange of the part you are fitting through to your exuast,
then drill your exuast with a 5mm drill , you will then need a 6mm tap to thread the 5mm holes out to a 6mm thread. go buy yourself 2 stainless steel 6mm x 12mm socket head cap screws . and bobs your uncle.

hope this is helpfull to you in some way.

[robracer]

my neighbors must want to kill me.

have you asked them if this is the case? Does it bother them? if so thell them to HTFU

[Jonno]

By the looks of the hex head screws in the pic' they are around M6 possibly s/steel, I would assume the end wall of your can would be fairly thin, if it isnt do as above and use some cutting compound especially if it is stainleess steel.. If it is thin walled then I suggest as follows:
I would think 2x M6 "nutserts" be popped in place after pre-drilling the correct size hole would be the go, "nutserts" are a threaded nut that is used behind thin metal, it folds each side of the metal wall like a pop-rivet then you can screw in a nice and tidy propper screw into it simular to spot welded nuts. Thus giving more screwing goodness

Anyhow, the tools for inserting ya nuts are too exy for just doing two holes, some engineering places such as truck body builders or sheetmetal shops would have them, they should be able to do them easily within 10mins.

Failing that a quick and rough way but not the correct way is to use the biggest self tapping screws you can put in! Obviously a smaller pre drilled hole would help with this.

HTH


edit* If you live near Knox Vic I can have a good mate put them in for you.

[maraach]

I will get pics up tonight. I wish it was just the absence of the screw's.

However, just to *try* and describe without a picture, im missing the part with the screw hole s completely. It is just the exhaust exit spout without anything in it at all - just a hole straight through. Cant find any google pics to show what i mean...

[maraach]

my neighbors must want to kill me.

have you asked them if this is the case? Does it bother them? if so thell them to HTFU

i haven't asked as such.. the fact that they refuse to talk to me after starting it a couple weeks ago at 8am on a Saturday leads me to believe it is the case though.....

[photomike666]

8am on a Saturday, they really need counciling if that upset them. Bounce it off the rev limiter at 6am on a Sunday and they will never complain about tick over at 8am again

[BikerBoy]

i've yoshi TRS pipes on my bike, they came with removable baffles -

the baffles really do the trick, cut noise down a lot but makes your bike sound like a 50cigi a day weezing smoker.

How old is your RS3 ?


You could get it re-packed, chances are your packing has burnt out making our pipe even louder.
yoshi recomends repacking every 5000kms.

keeps the noise down and your pipe from discolouring from heat.

otherwise, stick the baffles in and get the bike retuned. ?

[jl4049]

seperate your exhaust at the link pipe, force a coke can in there after you poke a heap of holes in it. Re-attach muffler, hey presto quiet bike. Works for the EPA Best bit is after one good hard ride the can is almost gone and easily removed.

[maraach]

Yeah my neighbours are a piece of work... but that's another story.

As for putting the baffle in... it isn't quite that easy, there is nowhere to put the baffle (hence my problem).

Exhaust is virtually new. Where i messed up is i assumed all of the yoshi exhausts came with, and could use the low volume insert (the "fits all yoshi rs-3 end cans, comment kind of lead me to believe that.. as well as all the others i have seen having them). All my friends who have the exhausts have the removable baffle, and i just assumed every exhaust would have it.

Here is the pic, as you can see it hasn't got the holding plate/screw spots for the baffles shown in the earlier link. I spoke to the importers of yoshimura and they told me that the model i've bought is probably over 3 years old (not surprising seeing its a zx9r), and at the time, they were supplied without the provision for baffle insert. Basically my options are (according to them) to buy a new end-cap with the screw holes ($170 + shipping, 2+ month waiting time), buy rivets and the end cap holder ($29.95), drill out all the rivets with a drill press (which i don't own), remove the end cap, put the new one on, rivet it in, and whola put in the low volume insert. I'm just sure there must be another way... but maybe i am wrong.

So far my idea's consist of drilling two holes in the end pipe, and then mounting l-brackets on the low volume insert and using two screws through the pipe into the brackets to try and hold things in place.

As for getting the bike re-tuned, not really looking at that option at the moment.. $700 odd was spent getting it re-jetted and dyno tuned to run properly with this exhaust... And honestly, it runs great - no flat spots, tons of torque, smooth and responsive... everything you could ever ask for. To go out and spend a similar amount so i can have it a little quieter, sometimes, kind of defeats the purpose. And really the bike runs amazingly well, and in my mind sounds pretty great as well. I do accept it isn't everyone's cup of tea though, and just want to try and keep the peace a little. What i'm really worried about? Is that they decide to call the cops and they defect the bike. It's not the loudest bike out there by a long shot, and is pretty modest in reality... however dont underestimate the meddling power of two 60 something year old retired busy bodies who have a history of complaining to my real estate agent because they believed trimming the hedge out the front of my house once a month wasn't frequent enough and i should sweep up the leaves in my driveway daily.....

And before i get the "why did you buy the exhaust then", answer is, well one because i think they look and sound great, and two it was a brand new yoshimura rs-3 full stainless 4-2-1 system, carbon fibre end can, for a 2000 model zx9r. Brand new, never used. Reduced from $2199, to.... $489 (cheaper than i could have gotten the end can only). They even threw in a second titanium end can in case anything happened to the first one for an extra $280.

[maraach]

edit* If you live near Knox Vic I can have a good mate put them in for you.

Dont happen to have any friends in Sydney do you?

[maraach]

seperate your exhaust at the link pipe, force a coke can in there after you poke a heap of holes in it. Re-attach muffler, hey presto quiet bike. Works for the EPA Best bit is after one good hard ride the can is almost gone and easily removed.

sounds almost crazy enough to work..... i take it you are speaking from experience here?

[6maniac]

Option 2 - ride to MadKaw's - drink his beer and the experts will fix it !

[maraach]

Option 2 - ride to MadKaw's - drink his beer and the experts will fix it !

This sounds like the best idea ever

I don't know if Madkaw would agree though.... maybe i can come wearing my neck warmer and come with a peace offering of a case of beer