Bolt-On Cheap Exhaust Option

2LZ · 08-07-2016, 04:31 PM

Hi all,

In the never-ending quest to make any bike run better, I was in deep anguish about having that cat in the stock bazooka........but being cheap, I didn't want to spend a fortune. I mean, a 1200.00 Yoshi would have been nice but.....

So, I hunted around and ordered this. It's good for up to a 600cc so I figured, why not? If it doesn't work on the RX3, I'll try it on one of my other rolling stock. It also has a removable baffle for those who like loud.

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

I started by whacking the stock muffler off as close to the muffler to leave as much flange as possible for mounting the new set-up. I even took a little weld. Finish the end of what is now the mid-pipe off on your grinding wheel and brush. Note the cat. Just a minor obstruction.

I then went by O'Reileys Auto parts and picked up a 1.5"-2" exhaust adapter. They have them stocked. It ran about 3.50. (Pt#548506) After cleaning this up, cut a cross (4 slits) in each end for crimping purposes (pic only shows one end, do both), then paint with your favorite BBQ black paint. Make the slits deep enough for the width of the clamps you'll be using. I prefer T-Bolt clamps. They aren't cheap but by far the best and you can really bear down on them. I still have one more clamp coming for the 2" end, hence the hose clamp for testing purposes. I'll try to mount both springs on the T-Bolt clamp when it gets here. If not, one will suffice. It's a dang snug fit.

The muffler comes with an adapter. Nice piece too. Feel free to whack the 1.5" end off of it....or do what I did and just reverse it and tap it into the muffler. Restriction? Possible....but no where near as restrictive as the cat. I did mark it with a Sharpee in the middle so I could make sure I was seating evenly on both ends of the adapter. Each end is about 1/2" inch+ inserted.

Whack one of the mounting flanges off the stock muffler. You'll need it for mounting the big clamp that goes around the muffler (included). Then measure and drill a hole on the other end of the flange where you'll need it.

Anyway, turned out nice, I thought. I went for a test burn after resetting the ECM and yes, it runs better. A little friskier but I noticed it most at cruise. I didn't need 1/3 throttle to hold cruise speed. Just a crack of throttle did the job. I can't wait to get it back together and do more miles to get the ECM set up properly.

Louder? yes...but not so much it's a problem at all, in my opinion. After all, the stocker isn't that quiet anyway.

So there you have it. A lighter (about 5+ pounds, estimate), attractive, freer flowing, bolt-on muffler for under 100.00....and it has a nice little growl. I'd post a vid if I knew how. ;-) Workin' on my GoPro as we speak.

2LZ · 08-07-2016, 04:45 PM

Here's an end shot so you can see how it looks out the backside. Clears nice, not close to any plastics.
Note: Shameless self-promotion pic of Mrs. 2LZ doing her best Vanna White imitation. The upside is now you can see how the new muffler compares to the stocker.

2LZ · 08-07-2016, 08:15 PM

I thought while I had it on the rack, I'd take out the baffle to see how it sounded. Loud. Got it....
In the meantime, for a muffler that's supposed to fit a 600cc bike, the popping on my hand behind the pipe wasn't very much. Once the baffle was out, other than the (removable) block at the end to stop the Rangers coat hanger, there was only 3 sets of three holes (9) to let the exhaust gasses out! WTH!? Cool! It's tune-able! So, instead of 9 holes, I busted out the drill press and doubled it to 18. Much better popping on the hand now and no real noise difference!
Chompin' at the bit now to take her out. Need that clamp so I can put the bags back on.......

detours · 08-08-2016, 12:24 AM

Looking good, 2LZ ! Thanks for the link and write-up!

dpl096 · 08-08-2016, 10:15 AM

Well done 2LZ .... I'm thinking this is a mod for me

You've really gotta learn how to load vids .. it's idiot proof easy and I'm the poster boy to attest to it!

BlackBike · 08-08-2016, 01:11 PM

2lz...Mechanical maestro

Don't get too carried away with video, I can't afford the download stream

FastDoc · 08-08-2016, 02:51 PM

Remarkably nice clean job, 2LZ. I bet may Zongites will be following in your footsteps on this one. I bet you cut off 5+ pounds there.

david3921 · 08-08-2016, 10:08 PM

Looks nice. Do you think you'll have to rejet?

Azhule · 08-08-2016, 10:18 PM

No jetting on the RX3 in N. America, although a ECU Fuel Mapping will help these engine A LOT from the looks of the roller coaster ride the hp/torque curve shows on the stock bikes

2LZ · 08-08-2016, 11:07 PM

Quote:

Originally Posted by Azhule

No jetting on the RX3 in N. America, although a ECU Fuel Mapping will help these engine A LOT from the looks of the roller coaster ride the hp/torque curve shows on the stock bikes

Yes. A remap option would help tremendously on both injector pulse width and swinging the timing advance to a more performance grid....BUT...it has to pass CARB and EPA to start with, so anything like this would have to be done by either CSC or a third party and installed after the fact.
In the meantime, it is a closed loop system running off of an O2 sensor. That O2 sensor will tell the ECM "I need more fuel" when the breathing is opened up "to a point" on the stock mapping.

2LZ · 08-08-2016, 11:11 PM

Got the bars and bags mounted and back on tonight. As you can see in the first pic (background), I shimmed the bracket out "one 5/16th nut" as it was very close to the bag bar...but not quite touching. I bought some space. Turned out nice. Now you can see what it looks like with the bags....

2LZ · 08-08-2016, 11:23 PM

Sound: It sounds about the same at idle. Maybe a tad more aggressive.
On the rev, it's got a growl but not too bad at all. Like I said, the stock muffler wasn't quiet when you open the throttle anyway. It does have a nice sound, when on it, more "performance" sounding....but come on folks, it's like trying to make a V6 sound like a V8. No amount of piping will make it sound like it has more CC's. You back off at cruise and it stifles down some. Livable for sure to me.

Power: Non-Scientific seat of the pants "Butt Dyno".
Quicker throttle response in neutral. Snappier.
Actually able to roll it on without dropping a gear under 5k! About 4-4500, just start to roll on the throttle (not spanking it) and it will catch up with itself! That's an improvement. These normally have "zero" under 5k.
After 5-5500k....marked difference. Between 5 grand and redline, definitely more crisp and more pull. Actual acceleration. Not like "DUDE! IT'S GOT A BLOWER!" kind of acceleration....but it's come to life. Not near as much "BUUUHHAAAWWWWW" when you hit it after 5k.

Cruise: Less throttle needed to maintain cruise. More crisp response.

I'm still going to tune with the baffle some more. I think another set of three holes.

CSCDude · 08-09-2016, 07:30 AM

That looks very good, 2LZ.

pyoungbl · 08-09-2016, 09:27 AM

It would be very interesting to see dyno figures. In many cases these mods do not actually produce more hp or torque, in fact it's usually the opposite even with new mapping for the ECU. I saw that on the last two bikes I had on a dyno. They felt like they ran better (and at low rpm the bikes did run smoother) but the hp only changed between 1% and 3%. Fuel mileage suffered quite a bit.

Peter Y.

2LZ · 08-09-2016, 09:40 AM

Quote:

Originally Posted by CSCDude

That looks very good, 2LZ.

Thanks Joe....and thanks for the great China trip. I checked in every day. Not sure how you can eat so dang much and still lose weight though ;-)

08-07-2016, 04:31 PM	#1
2LZ Join Date: Mar 2010 Location: Volcano, Ca Posts: 7,065	Bolt-On Cheap Exhaust Option Hi all, In the never-ending quest to make any bike run better, I was in deep anguish about having that cat in the stock bazooka........but being cheap, I didn't want to spend a fortune. I mean, a 1200.00 Yoshi would have been nice but..... So, I hunted around and ordered this. It's good for up to a 600cc so I figured, why not? If it doesn't work on the RX3, I'll try it on one of my other rolling stock. It also has a removable baffle for those who like loud. https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1 I started by whacking the stock muffler off as close to the muffler to leave as much flange as possible for mounting the new set-up. I even took a little weld. Finish the end of what is now the mid-pipe off on your grinding wheel and brush. Note the cat. Just a minor obstruction. I then went by O'Reileys Auto parts and picked up a 1.5"-2" exhaust adapter. They have them stocked. It ran about 3.50. (Pt#548506) After cleaning this up, cut a cross (4 slits) in each end for crimping purposes (pic only shows one end, do both), then paint with your favorite BBQ black paint. Make the slits deep enough for the width of the clamps you'll be using. I prefer T-Bolt clamps. They aren't cheap but by far the best and you can really bear down on them. I still have one more clamp coming for the 2" end, hence the hose clamp for testing purposes. I'll try to mount both springs on the T-Bolt clamp when it gets here. If not, one will suffice. It's a dang snug fit. The muffler comes with an adapter. Nice piece too. Feel free to whack the 1.5" end off of it....or do what I did and just reverse it and tap it into the muffler. Restriction? Possible....but no where near as restrictive as the cat. I did mark it with a Sharpee in the middle so I could make sure I was seating evenly on both ends of the adapter. Each end is about 1/2" inch+ inserted. Whack one of the mounting flanges off the stock muffler. You'll need it for mounting the big clamp that goes around the muffler (included). Then measure and drill a hole on the other end of the flange where you'll need it. Anyway, turned out nice, I thought. I went for a test burn after resetting the ECM and yes, it runs better. A little friskier but I noticed it most at cruise. I didn't need 1/3 throttle to hold cruise speed. Just a crack of throttle did the job. I can't wait to get it back together and do more miles to get the ECM set up properly. Louder? yes...but not so much it's a problem at all, in my opinion. After all, the stocker isn't that quiet anyway. So there you have it. A lighter (about 5+ pounds, estimate), attractive, freer flowing, bolt-on muffler for under 100.00....and it has a nice little growl. I'd post a vid if I knew how. ;-) Workin' on my GoPro as we speak. __________________ "Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350 Last edited by 2LZ; 02-06-2019 at 10:18 AM.
	7

08-07-2016, 04:45 PM	#2
2LZ Join Date: Mar 2010 Location: Volcano, Ca Posts: 7,065	More pics Here's an end shot so you can see how it looks out the backside. Clears nice, not close to any plastics. Note: Shameless self-promotion pic of Mrs. 2LZ doing her best Vanna White imitation. The upside is now you can see how the new muffler compares to the stocker. __________________ "Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350 Last edited by 2LZ; 02-06-2019 at 10:18 AM.
	3

08-07-2016, 08:15 PM	#3
2LZ Join Date: Mar 2010 Location: Volcano, Ca Posts: 7,065	Bonus! I thought while I had it on the rack, I'd take out the baffle to see how it sounded. Loud. Got it.... In the meantime, for a muffler that's supposed to fit a 600cc bike, the popping on my hand behind the pipe wasn't very much. Once the baffle was out, other than the (removable) block at the end to stop the Rangers coat hanger, there was only 3 sets of three holes (9) to let the exhaust gasses out! WTH!? Cool! It's tune-able! So, instead of 9 holes, I busted out the drill press and doubled it to 18. Much better popping on the hand now and no real noise difference! Chompin' at the bit now to take her out. Need that clamp so I can put the bags back on....... __________________ "Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350 Last edited by 2LZ; 02-06-2019 at 10:18 AM.
	3

08-08-2016, 12:24 AM	#4
detours Join Date: Sep 2014 Location: Arvada, CO Posts: 1,004	Looking good, 2LZ ! Thanks for the link and write-up! __________________ Red 5 standing by! 2015 CSC red RX3 with 19" front wheel, Shinko 804/805, skid plate, tall seat, 13T/45T sprockets, progressive shock, Winyoochanok windshield, GENSSI LED headlight, SW-Motech tankbag, Shorai Lithium battery 2014 Ural Patrol
	1

08-08-2016, 01:11 PM	#6
BlackBike Join Date: Feb 2016 Location: George West, Texas Posts: 4,097	2lz...Mechanical maestro Don't get too carried away with video, I can't afford the download stream __________________ ***************************************** 2015 Bashan"Blaze" BS250GY-31 (DB-07K-250) GONE 2017 Suzuki V Strom 650 XT "We are all born ignorant, but one must work hard to remain stupid." ~Benjamin Franklin~
	1

08-08-2016, 10:15 AM	#5
dpl096 Join Date: Sep 2015 Location: East Central Hellinois Posts: 1,344	Well done 2LZ .... I'm thinking this is a mod for me You've really gotta learn how to load vids .. it's idiot proof easy and I'm the poster boy to attest to it! __________________ ************************************************ * " Time you enjoy wasting, is not wasted." - John Lennon “I predict future happiness for Americans, if they can prevent the government from wasting the labors of the people under the pretense of taking care of them.” ― Thomas Jefferson "If you don't know where you're going any road will take you there" ....George Harrison song
	1

08-08-2016, 02:51 PM	#7
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Remarkably nice clean job, 2LZ. I bet may Zongites will be following in your footsteps on this one. I bet you cut off 5+ pounds there. __________________ Happy to serve.
	1

08-08-2016, 10:08 PM	#8
david3921 Join Date: Feb 2009 Location: Michigan Posts: 1,028	Looks nice. Do you think you'll have to rejet? __________________ 2012 Kawasaki Versys 1984 Honda Magna V65 2016 Rhino 250 2016 Tao Tao 125D
	0

08-08-2016, 10:18 PM	#9
Azhule Join Date: Dec 2015 Location: CO Posts: 1,525	No jetting on the RX3 in N. America, although a ECU Fuel Mapping will help these engine A LOT from the looks of the roller coaster ride the hp/torque curve shows on the stock bikes __________________ "Think as you like... but this self proclaimed Professor is always right" - Buckshot "You never know what someone is hiding beneath their smile..." - NinjaTom - R.I.P.
	0

08-08-2016, 11:11 PM	#11
2LZ Join Date: Mar 2010 Location: Volcano, Ca Posts: 7,065	Follow up Pics Got the bars and bags mounted and back on tonight. As you can see in the first pic (background), I shimmed the bracket out "one 5/16th nut" as it was very close to the bag bar...but not quite touching. I bought some space. Turned out nice. Now you can see what it looks like with the bags.... __________________ "Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350 Last edited by 2LZ; 08-08-2017 at 03:58 PM.
	1

08-08-2016, 11:23 PM	#12
2LZ Join Date: Mar 2010 Location: Volcano, Ca Posts: 7,065	Performance and Sound Sound: It sounds about the same at idle. Maybe a tad more aggressive. On the rev, it's got a growl but not too bad at all. Like I said, the stock muffler wasn't quiet when you open the throttle anyway. It does have a nice sound, when on it, more "performance" sounding....but come on folks, it's like trying to make a V6 sound like a V8. No amount of piping will make it sound like it has more CC's. You back off at cruise and it stifles down some. Livable for sure to me. Power: Non-Scientific seat of the pants "Butt Dyno". Quicker throttle response in neutral. Snappier. Actually able to roll it on without dropping a gear under 5k! About 4-4500, just start to roll on the throttle (not spanking it) and it will catch up with itself! That's an improvement. These normally have "zero" under 5k. After 5-5500k....marked difference. Between 5 grand and redline, definitely more crisp and more pull. Actual acceleration. Not like "DUDE! IT'S GOT A BLOWER!" kind of acceleration....but it's come to life. Not near as much "BUUUHHAAAWWWWW" when you hit it after 5k. Cruise: Less throttle needed to maintain cruise. More crisp response. I'm still going to tune with the baffle some more. I think another set of three holes. __________________ "Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350
	3

08-09-2016, 07:30 AM	#13
CSCDude Join Date: Sep 2014 Posts: 247	That looks very good, 2LZ. __________________ Joe www.ExhaustNotes.us
	1

08-09-2016, 09:27 AM	#14
pyoungbl Join Date: Feb 2016 Location: Portsmouth, Virginia, USA Posts: 632	It would be very interesting to see dyno figures. In many cases these mods do not actually produce more hp or torque, in fact it's usually the opposite even with new mapping for the ECU. I saw that on the last two bikes I had on a dyno. They felt like they ran better (and at low rpm the bikes did run smoother) but the hp only changed between 1% and 3%. Fuel mileage suffered quite a bit. Peter Y.
	0