Custom GSXR Exhaust on a 250!

[Panocha Rider]

Here is a video of the exhaust I put on my ninja. Hope you enjoy

Link to original page on YouTube.

[Panocha Rider]

Here is another.

Link to original page on YouTube.

[Alex]

Sounds good! Always hard to tell how loud it is from a video with nothing to compare it to, though. Do you have any close-up pictures of what the custom exhaust looks like on the bike?

[Panocha Rider]

If this is something that you want to do then you undertake this at your own risk I am not responsible for any damage that may occur. I will however be happy to take all of the credit for all of the positive results and comments that you receive as the result of this mod. Ok, nuf BS lets get to it!

This is what we hope the end result will be. Big thanks to Hokie_250for photo-chopping this up for me. A shout out to Donny at Desert Cycle Works for his help in this project.




You will need a 2006-2007 Suzuki GSXR 600 or 750 exhaust.



I am not going to get into the removal of the stock exhaust or the side panel, if you can not figure that out then you should not attempt this mod. Besides there are other DIY’s that cover that stuff.


Cut the cat away from the exhaust can. TIP: cut the can square not at an angle. Adjust the angle of the cut on the can as needed for installation.



Here is the can cut away from the cat. Remove the heat shield before cutting...DUH!



Here you can see the angle that we started with, it was adjusted to get the right fit.



Here is the bike with the stock exhaust removed. You will cut about 3 inches to get the new can to fit tight to the faring. Keep the stock exhaust “stop ring” (not sure of the real name). You will weld it to the exhaust pipe. (sorry there are not more pictures of this part. I say that all you need to do is hold the GSXR can up to the bike to get the amount you need to cut off the pipe.



This is a shot of the stock exhaust with the collar cut off. This is going to be the way you make the new can a slipon and not welded to your bike.



This is the collar after it is cut off the stock exhaust can.



Donny testing the fit before final welding of the stock collar to the GSXR can.



Donny welding the stock exhaust collar onto the GSXR can. Sorry I do not have better pictures of this phase.



Finished product!



Another shot of the finished product.



Here is a shot of the stock support bolt. This is sufficent to hold the very light exhaust.



This is a better shot of how the stock collar is welded to the GSXR exhaust to allow it to become a slip-on.



Some final points, this was the first go on this so there are some things I would do different if it was to be done again.
I would cut off the stock exhaust with a band saw or something other than a torch.
I would not pay for someone to do this if I had a welder and the equipment.
This is something that someone with good shop skills could do if they had the tools and took the time to get it right.
The total project time was about 2 – 2 1/2 hours. This is loud and if you want a quiet system then you need to add some type of baffling to the system. I recommend a rejet (which I have not done yet).

[Cochese]

What is the inside diameter?

I found a place to pick up universal baffle and fiberglass wrap but I need to know what the inside diameter is of the GSXR can so I can buy the right size...

I'm cross posting in the GSXR can threads.... don't kill me.