Exhaust

Thursty

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Well, I got my bike running somewhat ok, but am having a hard time dialing things in. Between timing, carbs, straight pipes, and a right side exhaust leak at the gasket, things seem to be all over the map on spark plug reads. I'd like to eliminate the problems potentially associated with the straight pipes before moving forward with fine tuning. I originally got the bike with stock pipes on it, however, they had a dirty exhaust leak that was making it hard to diagnose problems... Which is really the only reason that the bike even has straight pipes right now...

ANYWAYS, what I'm wanting to do is utilize the old stock pipes to customize my own, and make homemade baffles. Was wondering if anybody has any tips, tricks, or things to watch out for in making my own? I'm 'hoping' to create a low, deep sound, rather than a raspy, higher end sound. If that makes sense? Also, eliminating (if possible) backfiring would be nice... Anybody thought of replicating the baffles made in this video for their motorcycle?


Anyways, looking forward to hearing some ideas and opinions.
 

jpdevol

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Just depends on what ya want in terms of style, fitment and sound.
I think your stock header pipes should be 1.5" OD (verify that), if so, a shorty megaphone style or dunstalls would work. Weld-up the inner pipe to the outer pipe at the end of header and clamp 'em on.

https://www.mikesxs.net/12-in-stain...sal-cone-muffler-fits-1-1/2-in-exhaust-g.html

Or you could make your own using a "builders kit" make baffles or buy off-the-shelf baffles

https://www.tcbroschoppers.com/coll...a-xs650-builder-exhaust-kit-1-5-inch-diameter

https://www.denniskirk.com/drag-specialties/steel-baffle-ds-202019.ph44738.prd/H44738.sku
 

Thursty

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The baffles in the video you posted look like way too much work. Baffles can be made very simply. Here's how I make mine, used by me in dozens of XS650s that I have resurrected:
https://www.xs650.com/threads/homemade-baffles-for-short-pipes.26822/
First thing I tried was a cheap $10 emgo silencer, that I would say is similar in functionality to your homemade baffle. I started with 8", and cut it down 1.5" at a time. After cutting it down to about 5", I kind of lost interest in it, as it didn't achieve a deep enough tone that I'm looking for in the idle. Maybe I just need to cut it down more based off your post and homemade baffles? I had an old set of original mufflers that had an exhaust leak, and cut them down to just before the equalizing pipe. I fabricated a patch and welded them up. I can post pics when I get home tonight. What I'm looking for is a 'deep', loud, lumpy idle, but not blow the ears off my neighbors at high rpms. My uncle has a set of pipes that achieve it really well, and am wondering if I should just bite the bullet on em?
 

Thursty

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Just depends on what ya want in terms of style, fitment and sound.
I think your stock header pipes should be 1.5" OD (verify that), if so, a shorty megaphone style or dunstalls would work. Weld-up the inner pipe to the outer pipe at the end of header and clamp 'em on.

https://www.mikesxs.net/12-in-stain...sal-cone-muffler-fits-1-1/2-in-exhaust-g.html

Or you could make your own using a "builders kit" make baffles or buy off-the-shelf baffles

https://www.tcbroschoppers.com/coll...a-xs650-builder-exhaust-kit-1-5-inch-diameter

https://www.denniskirk.com/drag-specialties/steel-baffle-ds-202019.ph44738.prd/H44738.sku
I also have a set of cheap, emgo shorty's. The sound at higher rpms is ok, but idle is super quiet. My uncle suggested modifying the removable baffle via removing/adding muffler insulation. Again, I'll post pics tonight with descriptions.
 
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