Yamaha XJR1300 2002
How it works.
The essence of the modification can be seen in the first diagram showing the change in exhaust gas route before and after the modification. Basically all that will happen is that the final exhaust expansion chamber is bypassed by replacing the long tube buy a shorter stubby tube. The two tubes have approximately the same volume.
Pre-make the Stainless steel tube and plate for the modification
I would recommend contacting FUEL
Performance Exhausts who will make the modified plate and tube for you.
They have all the diagrams and fitting is an easy DIY job.
If you are good with Stainless steel metal work and want to do a full DIY
this is what you need to know.
- The tube and plate is all made from stainless steel.
- Make a steel plate with the external diameter exactly the same as the original tube shield normally 110mm diameter and a 32mm hole in the center.
- Cut a tube with a total length of 80mm and an inside diameter 30mm, outside 32mm.
- Weld the tube in the plate with 28 mm sticking out one side and 52mm on the other.
Modification Instructions
- Drill out the three rivets holding the black shield and the tube shield from the end of the original exhausts. Remove both and clean them as they are going to be refitted later.
- You should at this point see where the original tube is welded to the exhaust. At this point you can use a good metal drill (5mm does the job) and drill a lot of holes around the tubes welding or use a metal 34mm rotary cutter. If you have used the drill you may need a cold chisel to join cut between the holes.
- With a hammer, you gently hit the pipe until it moves. Then with a pair of pliers, grab the tube and pull it out. The removed tube can be dumped and any ruff edges left in the exhaust cleaned up.
- At this point the original shields are placed on top of the pre-made modification plate and tube. Carefully marking the position of the three securing holes drill the plate ready for fixing with new rivets.
