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http://groups.yahoo.com/group/W650riders/                  21/03/2011          W650
Subject

W650 – Exhaust Modification


Modification of the W650 Stock Exhaust


From the W650’s stock exhausts you can obtain a sound with more ‘body’ by removing
the inside baffles.
Body means     - louder but far from antisocial
               - more burbling
               - slightly noticeable on idling
               - noticeable and authoritive on accelaration
               - gorgeous on decelaration


Disclaimer     - this document is NOT an official Kawasaki publication
               - Kawasaki and Kawasaki W650 are trademarked names
               - the issuer takes no responsibility whatsoever
               - parts of this document are taken from www.w650-france.com
               - parts of this document are taken from www.w650.de
               - altering exhausts is a violation of law in some countries




                                    This is not an official Kawasaki Publication
                                                                    Type of document            Page X of Y

                                                                    Modification                Page 2 of 6
Issuer                             ny name                          Date                Model

http://groups.yahoo.com/group/W650riders/                           21/03/2011          W650
Subject

W650 – Exhaust Modification

Skills needed for the modification
          - basic home appliance skills
          - you do not need to be a trained or even skilled mechanic or a mechanic at all
          - 1 person can do the job, no assistance needed
          - nothing has to be taken off the bike (eg the exhaust system stays on)


Time needed for the modification
          - 60 minutes should be enough for both exhausts


Tools needed for the modification
  Drilling machine with a bit for metal machining

  A dremel is better : safer, more precise, faster, but not
  everyone has got one
  Dremel is a trademark name and as such copyrighted. Any machine from
  another make will do offcourse...

  Mole-Grip, if you don’t have one, ordinary pliers will do




  Special tool : exhaust extractor (explained further down)




  Hammer




                                             This is not an official Kawasaki Publication
                                                                  Type of document                                 Page X of Y

                                                                  Modification                                     Page 3 of 6
Issuer                           ny name                          Date                 Model

http://groups.yahoo.com/group/W650riders/                         21/03/2011           W650
Subject

W650 – Exhaust Modification




Something you should know about the exhaust


                                                                  This is what the exhaust looks like

                                                                  The green looking eye is how you look at it in
                                                                  Figure 2)




Figure 1


But you cannot see what is in the inside, here is a drawing attempt to show you :


  The black out line is the chrome exhaust (1) as
  you can see it in picture 1.

  The green stuff is a ring (2) inside the chrome
  exhaust (1). It is firmly fit into the chrome
  exhaust (1) and the baffle (3) is welded to it.

  The baffle (3) , in blue, is a metal tube full of
  holes.

  In orange you see the wrapped baffle(4), it looks
                                                                  Figure 2
  like some kind of cloth.

  The red dots (5) is where the baffle(3)is welded to                    You are looking from the top of the bike, see picture 1
  the ring. (2)



This modifaction is about :
           - getting the blue stuff out (number 3)

           - getting the orange stuff out (number 4), this will happen automatically when getting the blue
           stuff out.

           - the green ring stays inside on my bike, no special reason for doing so, except that it visually
           breaks the line of the exhaust opening and therefor it is a bit nicer to look at.

           However, the ring did not exit this procedure undamage. You can see where I hit it with the drill,
           leaving clear metal spots where the rest of the exhaust opening is black of smoke but I have good
           hopes that over time, these spots will turn black again.




                                           This is not an official Kawasaki Publication
                                                                 Type of document              Page X of Y

                                                                 Modification                  Page 4 of 6
Issuer                          ny name                          Date                Model

http://groups.yahoo.com/group/W650riders/                        21/03/2011          W650
Subject

W650 – Exhaust Modification


  And here is what comes out.

  Note that the baffles are damaged so basically
  these parts are waste and this makes the operation
  irreversible.

  Please compare Figure 3 with Figure 2 !




                                                                 Figure 3




Procedure
A. The Special Tool : Exhaust Extractor
The Extractor is a very basic tool. You will use it to hook up behind the baffle inside the exhaust and hit it
on the other side in order to pull out the baffle.

Items needed       - Strong piece of wood, this is where you will be hitting on with the hammer

                   - a metal thread (for the prototype an M10 x 100 was used) a minimal length of 50 cm is
                   recommended. The baffles are approx 30 cm long and you need to hook behind them
                   and have enough space to hit with the hammer.

                   - bolts and spacers



Not the best picture but the idea should be clear,
this is the part that you will insert into the exhaust
opening. The spacer will hook behind the baffle
and then you can pull it out.

Make sure the metal thread, spacer and bolt are
sturdy material and good quality. You don’t want
to end up with them braking off and falling into the
exhaust !
                                                                 Figure 4


At the other side of the metal thread, you attach a
piece of wood which you will hit with the hammer
in order to get the baffle out.




                                                                 Figure 5




                                          This is not an official Kawasaki Publication
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Issuer                    ny name                          Date                Model

http://groups.yahoo.com/group/W650riders/                  21/03/2011          W650
Subject

W650 – Exhaust Modification

B. Doing the Job
1. Machining the welds off
                                                                  If you look closely to the rear of the exhaust,
                                                                  you will see that both on the left and the right
                                                                  INside of the exhaust there is a welding bubble.
                                                                  You need to get this off.

                                                                  The welds are represented by red spots in the
                                                                  drawing to the left

                                                                  Use the Drilling machine or dremel to get them
                                                                  off as clean as possible!


Do not damage the chromed outside of the exhaust, take your time !

2. Insert the Special tool into the exhaust and use the hammer to get the baffles out
                                                           The idea behind the Extractor is to hook something
                                                           behind the baffle and pull the baffle out, this is
                                                           done by hitting on the wood piece with a hammer :

                                                           Insert the extractor as far as you can and then pull
                                                           it back, trying to hook it up behind the muffler.

                                                           See where the bolt and spacer (1) hook behind the
                                                           baffle.

                                                           Note that the red dots (see figure 2) have gone !




  Figure 6


3. Hit with the hammer
                                                           I needed max 5 good hits in order to get the baffles
                                                           far enough out to grab them with the mole-grip (or
                                                           pliers) and then pulling them out.

                                                           Try to move the extractor to different sides of the
                                                           baffle for every hit in order to have action on a
                                                           larger surface of the baffle.

                                                           So for the first hit take spot 1, then spot 2 and so
                                                           on.... as far as it is possible to move around and
                                                           aim the extractor.

  Figure 7




                                    This is not an official Kawasaki Publication
                                                                    Type of document                            Page X of Y

                                                                    Modification                                Page 6 of 6
Issuer                             ny name                          Date                Model

http://groups.yahoo.com/group/W650riders/                           21/03/2011          W650
Subject

W650 – Exhaust Modification

3. Apply the mole-grip (or pliers)
The cleaner you have got the welding off in step 1 (1. Machining the welds off) , the easier the baffle will
come out by applying the hammer.

Once the baffle has come out some 5 to 20 mm, you can grab it with the mole-grip or pliers and pull it
out. Both the metal tube and the cloth looking thing will come out at the same time.

Of course you will have taken the extractor out first !

Pull the baffle out and the job has been done. Obviously the procedure is identical for both baffles.



4. That is it !
 This is what it looks like after a succesful
 operation.

 See the ring sitting in there ?




                                                                    Figure 8 : taken from www.w650-france.com




5. Notes
If you follow the above procedure, the metal ring will still be in there. Maybe you want to get it out too?

It may feel and look as a pretty harsh modification but it is plain simple and straightforward.

This action is irreversible !




                                             This is not an official Kawasaki Publication

				
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