Aftermarket Exhaust

[cedmund00]

Hey Gang,

I am thinking of losing the stock exhaust and catalytic converter on my 1993 FJ1200. I figured run 4-1 and find a slip-on can to run on one side. Anyone have any tips, tricks, suggestions, warnings or basic advice please that would be Sweeet.

Thanks,

Craig

[wheels]

hey  peoples does anybody know if racerrad is about or gone away for the weekend  he's a hard person to catch up with cheers darren

[Dan Filetti]

Hey Gang,

I am thinking of losing the stock exhaust and catalytic converter on my 1993 FJ1200. I figured run 4-1 and find a slip-on can to run on one side. Anyone have any tips, tricks, suggestions, warnings or basic advice please that would be Sweeet.

Thanks,

Craig

Craig-

Do make sure, if possible you do not have to take it back off simply to change the oil.  Thar's a PITA.

Dan

[racerrad8]

hey  peoples does anybody know if racerrad is about or gone away for the weekend  he's a hard person to catch up with cheers darren

Darren,
          And all others here on the list. I do the FJ stuff as my hobby and I have to go to work my "day job". I work a great schedule, but it keeps me away from the shop and computer for four days at a time. I work a 4 on - 4 off schedule and my work days are 12 hour days. Add swing to that mix as well and you can see why I don't get to the shop or computer much during those days. (Today is an anomaly as I got held over at work for an extra 3.5 hours; I needed to sit and wind down before heading to bed...)

If you send me an email to rpm@swaybar.com, I will respond upon my first day back to the shop. In fact I usually spend almost half of my first day back on the computer answering questions, giving price quotes and help those that request it.

Darren, sorry your part did not go out on Friday but the post office would not take it without a last name and I did not want to make one up in case your I.D. was required to receive the package. It will head out on Wednesday when I get to the shop.

Thanks, Randy - RPM   

[Fudge]

catalytic converter? there is no cat on an FJ.

[Dan Filetti]

There's a collector though...

Dan

[andyb]

I am thinking of losing the stock exhaust and catalytic converter on my 1993 FJ1200. I figured run 4-1 and find a slip-on can to run on one side. Anyone have any tips, tricks, suggestions, warnings or basic advice please that would be Sweeet.

No cat on an FJ.

4-1 is okay, you'll end up with a flat spot around 6k (give or take) though.  4-2-1 (or 4-2-1-2) is better to reduce that at the cost of a bit of top end.  Most street riders would prefer a clean power curve instead of a rougher but slightly higher one (thus the 4-2-1), I'll wager.

Dan's right about the oil drainplug access also.  However, you can remove the pan (or buy a spare) and have someone weld in a bung in a different place.  It's just something to be aware of.

Also, centerstands are sometimes eliminated by the pipe.  Bigger bitch to lose that than the drainplug access, IMO.

As I see it, the options are:
-Stock
-Slipons, stock headpipes
-Stock headpipes, custom collector/box, custom link pipe, aftermarket cannister
-4-1 full system
-4-2-1 full system

For some reason I wonder if the XJR exhausts fit up with minimal massage, but they're difficult to get in the states.

[Flying Scotsman]

I am running a 4-1-2 exhaust and my muffler's are geting a bit rough.On the left side muffler the baffle rattles more than the right side.Inside the mufler at the front where the baffle locates is a welded bracket that went round the i.d. of the can.Mine is not there there are a couple of pieces still ther but the baffle is loose and not centered.My other muffler left side has hit the axle bolt and chewed it up on the outside.So what would the best replacement mufflers be for my 1100.I did post pics in the gallery and I think it's a Kerker pipe.I can measure pipe dia but I think its 2".Also untill I get new mufflers is there any way to pack the mufflers to stop the rattle they make.Mine have no packing in them.

[andyb]

Looking at your pictures, I do not recognize the exhaust used.  However, this picture shows clearly that the endcaps to the cannisters are held on by screws or rivets.  That indicates that they're rebuildable.

Take the cans off the bike.  Start the bike, just to hear the glorious racket of open pipes, just once, ensuring obnoxious neighbor isn't home.  Remove the endcaps, either by drilling rivets or unscrewing things.  They may be a bit tricky to remove though, some manufacturers use a high temp sealant that makes it require a bit of force.  Inside, you're going to find a perforated tube that may or may not come out (or may be destroyed, rusted to shit, etc).  If you can remove it by a bit of tugging/twisting, lovely.  You may also need to look at the front portion of the exhaust for screws/rivets... usually they're pretty simply assembled with a press fit on the inner (baffle) tube.

If you can get it out, clean everything up nicely and find packing material.  Lots of options, from Moose's product, to JCWhitney stuff, to heavy gauge (stainless) steel wool.  Pack it up and put it back together.  You can use masking tape to bind things down and make assembly easier, it'll burn off and not cause problems.  Do expect a bit of a stink and some smoke when you first get them hot after repacking, that's normal.


As far as replacement?  Depends on your budget, ingenuity level, and how good you are at making stuff fit.  Anything will fit, just some fit with less effort than others!

[Flying Scotsman]

I have had the baffles out the end caps are held in with 3 1/4-20 screws 1 of them rattles more than the other.I do plan on replacing them but I will try packing them till I do.I was tempted to start her up with no mufflers on her at all but I didn't.Baffles can come out in about 5 min so it could still hapen.
Who makes aftermarket mufflers so I can go look at some diferent options ?

[Flying Scotsman]

When I pack the mufflers I pack the outside of the baffle  only  right.

[andyb]

You can pack the inside too, but it'll make a hell of a mess blowing out the pipes! 

Between the perforated tube and the outer tube, yes.

[Flying Scotsman]

Thank you  

[Flying Scotsman]

Took out the baffles and went for a ride.I must say it sounds good.I wonder if I took the mufflers off if I would be shooting flames out the pipes.FJ was fairly quiet unless i gave it some gas.

[Harvy]

For some reason I wonder if the XJR exhausts fit up with minimal massage, but they're difficult to get in the states.

Indeed they do.......Klavdy was using them for a while.

Harvy