world101
04-23-2002, 07:48 AM
i'm not totally done with the mod yet, but i'm posting my progress so far...
this past weekend, i decided to change the oil and coolant in the gixxer. i noticed there was an air leak somewhere in the exhaust, so i moved the radiator aside and tightened the header bolts... this seemed to fix the problem...
as i was messing with the exhaust, i noticed that my D&D headers had a mid pipe... i took the exhaust apart and figured out that if i twist the midpipe (about it's center axis), it makes the can sit higher... this was awesome, because i've always wanted a high-mount exhaust... the only problem was that it stuck way too far away from the bike... i was going to mount it like that anyway, but stumbled on something else...
i pulled off the midpipe completely and tried turning it 180 degrees... well that didn't work... the can would slip over the end of the midpipe that WAS mounted to the header, but the other end (which was previously mounted to the can) would not fit over the header... it seemed as if they were the same size diameter... well with more brain racking and trying to figure out how to make this thing work, i noticed that there was an aluminum baffle on the inside of the midpipe... so i performed surgery with the handy dremel and removed about 3 inches of the baffle inside the midpipe... it worked flawlessly and now the end slides perfectly over the end of the header...
next task was to figure out how to high-mount the exhaust while keeping the passenger peg... i made a bracket that hangs down from the subframe (where the passenger peg mounts to the subframe) to the peg... i had to get the aluminum and a shorter allen bolt from home depot... this bracket brings the back mount of the passenger peg down, thus pushing the peg assembly forward... i mounted the exhaust ring to the rubber bushing that the tail (the nipple on the inside) would normally push into...
i also twisted the passenger peg 180 degrees and put a screw through the center of the peg (on the inside of the bracket assembly)... this makes the peg non-functional (ie: it doesn't close), but it's safer this way because it would fold up if someone put their foot on it... i'll post more detailed pics on this... but i plan to get round aftermarket pegs so it doesn't look so awkward...
i'm in the process of making another support that will mount to the normal exhaust mount hole on the peg assembly... i might end up cutting this off if it doesn't look good... we'll see...
more details and pics coming soon... for preliminary pics visit this link (http://filebox.vt.edu/users/bstein/high-mount.htm)
http://filebox.vt.edu/users/bstein/hm_08.jpg
http://filebox.vt.edu/users/bstein/hm_09.jpg
[ 04-23-2002, 05:48 AM: Message edited by: world101 ]
this past weekend, i decided to change the oil and coolant in the gixxer. i noticed there was an air leak somewhere in the exhaust, so i moved the radiator aside and tightened the header bolts... this seemed to fix the problem...
as i was messing with the exhaust, i noticed that my D&D headers had a mid pipe... i took the exhaust apart and figured out that if i twist the midpipe (about it's center axis), it makes the can sit higher... this was awesome, because i've always wanted a high-mount exhaust... the only problem was that it stuck way too far away from the bike... i was going to mount it like that anyway, but stumbled on something else...
i pulled off the midpipe completely and tried turning it 180 degrees... well that didn't work... the can would slip over the end of the midpipe that WAS mounted to the header, but the other end (which was previously mounted to the can) would not fit over the header... it seemed as if they were the same size diameter... well with more brain racking and trying to figure out how to make this thing work, i noticed that there was an aluminum baffle on the inside of the midpipe... so i performed surgery with the handy dremel and removed about 3 inches of the baffle inside the midpipe... it worked flawlessly and now the end slides perfectly over the end of the header...
next task was to figure out how to high-mount the exhaust while keeping the passenger peg... i made a bracket that hangs down from the subframe (where the passenger peg mounts to the subframe) to the peg... i had to get the aluminum and a shorter allen bolt from home depot... this bracket brings the back mount of the passenger peg down, thus pushing the peg assembly forward... i mounted the exhaust ring to the rubber bushing that the tail (the nipple on the inside) would normally push into...
i also twisted the passenger peg 180 degrees and put a screw through the center of the peg (on the inside of the bracket assembly)... this makes the peg non-functional (ie: it doesn't close), but it's safer this way because it would fold up if someone put their foot on it... i'll post more detailed pics on this... but i plan to get round aftermarket pegs so it doesn't look so awkward...
i'm in the process of making another support that will mount to the normal exhaust mount hole on the peg assembly... i might end up cutting this off if it doesn't look good... we'll see...
more details and pics coming soon... for preliminary pics visit this link (http://filebox.vt.edu/users/bstein/high-mount.htm)
http://filebox.vt.edu/users/bstein/hm_08.jpg
http://filebox.vt.edu/users/bstein/hm_09.jpg
[ 04-23-2002, 05:48 AM: Message edited by: world101 ]