I'm getting a gixxer can for my bike. I know I've got to make up a flange & extend the pipe & make a new mount for the can.

My query is are aftermarket system pipes larger in diameter than the standard pipes? I'm just thinking of making a new system instead of just adding on to the existing.

Are there any 'rules' to stick to in regards to making a motorcycle exhaust?

Quote from: bubba zanetti on September 19, 2006, 04:15:15 PM

My query is are aftermarket system pipes larger in diameter than the standard pipes?

Yes. I do not recall the size but it has been posted several times.

Quote from: bubba zanetti on September 19, 2006, 04:15:15 PM

Are there any 'rules' to stick to in regards to making a motorcycle exhaust?

No rules, just right. 

Sharper bends = less flow.
There are a lot of calculations that could be made or use of CFD sofware (Computational Fluid Dynamics), but following the basic design of what is available is a good starting point.

Aftermarket pipes are larger dia.
Cool.
Srinath.

You can go too large though and then you lose all your low end power.

Are you going to have a shop fabricate the system for you? If so I've always thought an underseat pipe would be pretty sweet. If you're look ing at buying an aftermarket header, I think they all come with a muffler anyways.

If you go custom, do something unusual and cool, because you'll end up spending as much as a pre made system, and you probally won't make any more power, so it's all about the cool factor 
have fun 

Quote from: ducati_nolan on September 19, 2006, 10:37:21 PM
You can go too large though and then you lose all your low end power.

Are you going to have a shop fabricate the system for you? If so I've always thought an underseat pipe would be pretty sweet. If you're look ing at buying an aftermarket header, I think they all come with a muffler anyways.

If you go custom, do something unusual and cool, because you'll end up spending as much as a pre made system, and you probally won't make any more power, so it's all about the cool factor 
have fun 

I'm getting a can from a K1 gsxr600.

I was thinking that I'm going to have to make a piece to go from the existing pipes to where I mount the new can, so I might as well make up some new headers. I was thinking about 1/4" larger dia to get it flowing a bit better.

I'm also thinking about putting pod filters on it as well 

I'll see when I get the can.

Thanks for the replies 

You should measure the V&H pipes and some other aftermarket pipes and use that size. I don't think that they're 1/4" larger than stock though, that would probally kill the lower end and not help the top end at all. I bet something more like 1/8" over stock would work well, but you can probally call the manufacturers or check out their website to find out what they use.

Also probally the most critical piece is the Y pipe, if that isn't really smooth you'll lose any power that you would have gained from the larger pipes.

I think the "lunchbox" filter is cheaper and flows better than individual pod filters, but exhaust should be done at the same time as the intake for the best gain in power. Of course you'll need to jet the carbs as well.

You should look into stainless pipes as well, that could look wicked 

I'm interested in how where you get the jets from and how much they cost you. Same with the K&N's.


I'm having all kinds of troubles at the moment trying to find US dealers willing to ship to Australia. 

Quote from: galahs on September 20, 2006, 04:42:12 AM
I'm interested in how where you get the jets from and how much they cost you. Same with the K&N's.


I'm having all kinds of troubles at the moment trying to find US dealers willing to ship to Australia. 

If you need some help, let me know. I can buy what you want then ship it to you.

speaking of 'cool factor"... anyone ever done a dual system, one on both sides?  I'm thinking of doing it but can't figure how to get it done.

Quote from: dgyver on September 20, 2006, 05:04:58 AM

Quote from: galahs on September 20, 2006, 04:42:12 AM
I'm interested in how where you get the jets from and how much they cost you. Same with the K&N's.


I'm having all kinds of troubles at the moment trying to find US dealers willing to ship to Australia. 

If you need some help, let me know. I can buy what you want then ship it to you.

Mate I might just take you up on that offer 

I have a few more avenues worth trying but if they don't work I'd be stoked if you could help me out.

I found a K&N lunch box today in the US for US$24.38 but they wanted to charge me US$60 to ship it out here. Surely a K&N filter doesn't cost $60 to post 

A quick look at the USPS website and it should cost around $30 US to ship a package that size. But there would also be the cost to ship to me. Just let me know. I have done this before for a bloke in the UK.

Oh yeah...last time I shipped a package to Aus, it took about 5 days.

I'm going to see if I can get these filters out here, so I'll let you know Galahs. If I have no luck I'll put my hand up for a filter to be shipped out as well.

With the exhaust I think the best thing to do is leave the original headers on & run new pipe from the Y piece to the new can.

BikeBandit.com has them for approx $45 and will ship them to Australia for $20 (US)

So thats about $83 Australian (delivered).



I have sent an email to Rocketindustries Australia (the Aus distributor of K&N ) asking them if they stock the lunch box (only the drop in replacement is listed).

You can probally cut the pipe at the old muffler and weld on a flange and bolt up the new can. It shold be easy to make a flange, just get some 1/4" steel plate, some bits and a drill press, then weld it on. You shouldn't need to make a pipe all the way from the Y unless you're doing something fancy.
Good luck 

I got a reply from Rocket Industries and the RU-2970 sells for apporximately AUS $100 but they are currently out of stock.

So when I ordered some parts today from Bikebandit.com, my shipping came up to $49 US, so I tryed adding another K&N to see the effect, guess what.  The shipping stayed the same.

So I now have two k&n lunch box filters heading my way.
I figure someone in Australia will want one and this'll help save them on shipping costs.

So bubba, if you can't get one locally I'm willing to send on my second one for cost plus shipping.


It ended up costing me AUS $57 ($43.17 US) and postage to Bathurst wouldn't be more than $10.


if only we lived in America! We could get our parts cheap cheap! 

I'll take the second one if bubba doesn't.

Quote from: galahs on September 21, 2006, 09:59:04 AM
I got a reply from Rocket Industries and the RU-2970 sells for apporximately AUS $100 but they are currently out of stock.

So when I ordered some parts today from Bikebandit.com, my shipping came up to $49 US, so I tryed adding another K&N to see the effect, guess what.  The shipping stayed the same.

So I now have two k&n lunch box filters heading my way.
I figure someone in Australia will want one and this'll help save them on shipping costs.

So bubba, if you can't get one locally I'm willing to send on my second one for cost plus shipping.


It ended up costing me AUS $57 ($43.17 US) and postage to Bathurst wouldn't be more than $10.


if only we lived in America! We could get our parts cheap cheap! 

I'll take it, thanks alot mate. 

PM me or email me with your details & I'll fix you up for it.

I wasn't too worried about the filter for the moment as I just ordered a Ventura bag & rack system for the bike.

Seems I should have ordered more!  Sorry s4gs, bubba got in first. I need to order a few more parts from the states soonish so I could add another filter to that order if that helps.

bubba, I'm heading to the Bathurst 1000, so depending on the shipment (I sure hope it arrives before then) I could actually meet you somewhere at Buthurst and give it to you there and save you postage?

I'll keep you updated. 

Quote from: galahs on September 22, 2006, 09:29:36 AM
Seems I should have ordered more!  Sorry s4gs, bubba got in first. I need to order a few more parts from the states soonish so I could add another filter to that order if that helps.

bubba, I'm heading to the Bathurst 1000, so depending on the shipment (I sure hope it arrives before then) I could actually meet you somewhere at Buthurst and give it to you there and save you postage?

I'll keep you updated. 

Sounds good.

Quote from: galahs on September 22, 2006, 09:29:36 AM
Seems I should have ordered more!  Sorry s4gs, bubba got in first. I need to order a few more parts from the states soonish so I could add another filter to that order if that helps.