De-catting a Gixxer 600 K8

[megawatt]

A friend of a friend turned up today. He had asked me if we could get rid of the 11lb lump of steel and chemicals that is his standard catalytic converter, make and fit a linkpipe to his carbon Yoshimura silencer. Got a shock when we removed the fairing, bloody headers are welded to the cat!!! So it was out with the angle grinder!!!

http://i145.photobucket.com/albums/r240/megawattblade/IMAG0875.jpg

http://i145.photobucket.com/albums/r240/megawattblade/IMAG0876.jpg

http://i145.photobucket.com/albums/r240/megawattblade/IMAG0877.jpg

http://i145.photobucket.com/albums/r240/megawattblade/IMAG0878.jpg

http://i145.photobucket.com/albums/r240/megawattblade/IMAG0879.jpg

We made a short coupling and blatted to my local TIG welder so he could weld it to the 4 into 1 section just after the Lambda probe.

Next we cut up some pieces of 304 stainless, two sets with 30 degree angles, offered em up, a bit of length adjustment and voila.

http://i145.photobucket.com/albums/r240/megawattblade/IMAG0881.jpg

http://i145.photobucket.com/albums/r240/megawattblade/IMAG0882.jpg

http://i145.photobucket.com/albums/r240/megawattblade/IMAG0883.jpg

Final welding and fitting of Mega clamps next week. Couldn't resist a test fire , so gaffer taped all the sections together and fired er up!!! Vids to follow.

Edited August 31, 2012 by megawatt

[uk190]

Good to see the old angle grinder still saving the day.

[iiisecondcreep]

Stupid question time: won't it fail its MOT on emissions without a cat?

[megawatt]

Thanks Martin, ya missed it this year in Winster didn't you

No Gayle, they don't do emissions tests on bikes for MOT

And a video;

http://i145.photobucket.com/albums/r240/megawattblade/th_VIDEO0076.jpg

[Joeman]

Great thread, planning similar with my bike soon

However, are you sure its not a K8?

My K7 has the headers detach from the cat, and doesnt have the nice round exit pipe from the cat.

http://www.hills-bikes.co.uk/images/part_images/large/751742_74040.jpg

The K8 has the headers welded to the cat, and the nice round exit pipe...

[megawatt]

You could be right Joe, don't know my Gixxers.

And a video, tubes held together with gaffer tape!!!

http://i145.photobucket.com/albums/r240/megawattblade/th_VIDEO0076.jpg

[Joeman]

You could be right Joe, don't know my Gixxers.

And a video, tubes held together with gaffer tape!!!

 

Either a K8, or maybe the started fitting this style of cat on the later K7's?

Doesnt realy matter anyway, as you've ripped out the offending parts and now it sounds awesome

I see you took the SET valve out too. Interesting to hear the owner's opinion on if that makes it feel any difference. Lots of debate on other forums about the SET valve. Some say its just a noise restriction thing, others say it boosts low/mid range torque. You'll need to pull the wire from the ECU to turn the "FI" light off

[megawatt]

Yer right Joe , I got it wrong and changed the title.

My mate hated the SET valve and was glad to get rid of it. He reckons it's much more responsive without and the bike doesn't lurch forward when the valve opens

[Stu]

SET valve? Since when did they start calling a EXUP valve a set valve? Let me guess Suzuki's "own" design

[Joeman]

Yer right Joe , I got it wrong and changed the title.

My mate hated the SET valve and was glad to get rid of it. He reckons it's much more responsive without and the bike doesn't lurch forward when the valve opens

 

LOL, im a Gixxer geek

I've disconnected my SET valve. Its made the bike sound much better at tickover, and i reckon its also made slow speed handling better, so like on small tight roundabouts, the power delivery is much more predictable without the SET valve.

[megawatt]

How you gonna remove the "silencer" from the K7 cat Joe? Can you run a thread when yo do it, pleeeeeeze?

[Joeman]

How you gonna remove the "silencer" from the K7 cat Joe? Can you run a thread when yo do it, pleeeeeeze?

 

yes, its a bugger... no nice round exit pipe like the K8

got a couple of options. Some people are just smashing the honeycomb out of the cat (gutting the cat) which apparently makes a difference and keeping it all looking standard. I already have a carbon cover which looks cool so thats one option.

Other option is to remove the cat completely and replace with cat replacement pipe and new silencer. The SET valve is on the header pipe on the K7, so that can either be lockwired open (its sprung to stay open, but apparently can flap at high revs) or remove it completely.

I might take a look this weekend if i get time... I'll have the bike up on paddock stands anyway as i'll be fitting the new +2 rear sprocket

[Harrydh3]

Some people are just smashing the honeycomb out of the cat

 

thats what ive done for every racecar i've built

hammer + chisel x vice/CAT = win

keep us posted mega sounds mean.

[megawatt]

My mate's linkpipe is finished! Made out of two pieces clamped together.

http://i145.photobucket.com/albums/r240/megawattblade/Exhaust%20stuff/IMAG0900.jpg

http://i145.photobucket.com/albums/r240/megawattblade/Exhaust%20stuff/IMAG0901.jpg

And a video. Double click on piccy.

http://i145.photobucket.com/albums/r240/megawattblade/th_VIDEO0077.jpg

[Tango]

Nice job Alan.....looks and sounds great......

[megawatt]

Thanks Bob.