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Modifying SE exhaust

Discussion in 'The Garage' started by Norwegian XS, Jan 9, 2010.

  1. Hi.

    This is my first post on this forum! :thumbsup:

    I've got exhuast from an XS650 SE that i like to modify.
    I would like to use the headers, but i seems like the exhaust are in one pice.

    Have any one tried to cut of the headers, and used them with other mufflers?
  2. inxs

    inxs xx

    - on mine the mufflers were welded to the header, the welds were hidden under a little cover...i carefully cut the welds with a cutting disc to separate
  3. What kind of mufflers did you use?

    Does someone know what kind of mufflers that will fit?
    I am building a cafe racer, and do like the Britstyle look.
  4. inxs

    inxs xx

    - a set of short stainless steel reverse cones also single skin stainless headers bent to the 'special' form - no balance pipe

    - get a set of reduction rings to adapt whatever muffler you use
  5. I've got some cut SE exhaust headers, and will grind down the weld that join the headers and the muffler.

    Then i need to find some aftermarket mufflers that will fit on the headers.
    Is there anyone who knows what may fit?
  6. KevC

    KevC XS650 Addict

  7. inxs

    inxs xx

    - separated, it looks like this...if i remember correctly the sleeve with the holes in it is 43mm diameter

  8. Just to confirm.. I measured a couple I had laying around and they are 42.75mm at the sleeve with the holes. :thumbsup:

    The tubing at the end is 31.75mm
  9. I just did this and now my bike runs like crap.. :doh:
  10. Downeaster

    Downeaster Everything in XS Top Contributor

    Just whacking off the mufflers with no other changes will do that. It screws up the jetting on the carbs.

    You need to either install some sort of muffler or baffle, or re-jet the carbs to match the new flow characteristics resulting from running straight pipes. Possibly (probably) both.

    BTW, the "correct" version of your signature line is "If it has tits, tires or tracks, sooner or later it's gonna cost ya." With nearly 50 years of experience, I can say without hesitation that no truer words was ever spoke...:(
  11. HA HA I guess I did miss a few things in my signature.. I tried re jetting and still didnt like the outcome. I just ordered some new carbs. and a few other goodies will be ordered tomorrow to fix the problem I hope.
  12. Downeaster

    Downeaster Everything in XS Top Contributor

    Rejetting can be a time-consuming exercise. I don't know that anyone ever gets it right the first time.

    There's a couple of good tech articles on it here.
  13. Garrett411

    Garrett411 XS650 Enthusiast

    Hey guys.

    Just tried cutting the stock mufflers off on a 79' XS. Got the weld cut and separated from the inner pipe but the muffle just doesn't want to let go. It feels like something is holding onto it from farther up in the muffler. Connecting pipe maybe? Any advice guys?


    Attached Files:

  14. XSLeo

    XSLeo XS650 Guru Top Contributor

    There is an inner tube as well as outer tube. Cut through both.
    You will find that once cut off you will see the inner and outer tubes easily. You need to get and adapter that fits on the inner tube. This adapter is what you clamp the new muffler too.
    the outer tube is just to look pretty not carry the exhaust.
  15. 5twins

    5twins XS650 Guru Top Contributor

  16. Garrett411

    Garrett411 XS650 Enthusiast

    Thanks for all the help guys! Got er all welded and wrapped now! Pretty good for a mornings work! Onto the bars and speedo/tach next!


    Attached Files:

    GaryS-NJ likes this.
  17. Jpwhit1

    Jpwhit1 XS650 Enthusiast

    Starting the process myself on 78'. Is the joint in the middle that connects both mufflers significant. I plan to cut where header and muffler come together and add after market mufflers. Aside from modified jetting is the jointed mufflers needed?

  18. Crossover isn't necessary.
    The '78......if it's a Special then the header is double walled. Refer to the post above by 5twins linking the PamcoPete mod.
    I saw through both pipes where the header joins the muffler......making sure to leave as much header as possible after the header to frame mount. I like the 27 inch Dunstall repro muffs myself. Other opinions may vary..........
  19. XSLeo

    XSLeo XS650 Guru Top Contributor

    All stock head pipes are double wall.
    The crossover pipe between the mufflers is to improve scavenging. Scavenging is where the exhaust flow helps the spent gases in the cylinder get pulled out and increasing the cylinder fill at lower to mid engine rpms.
    Removing it will have some effect but not that noticeable.

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