I took my wifes 500 exaust apart and built a 2 in to one for her . Pretty easy to do as long as you have acces to a wire feed welder .

Pic one is cuttin the headeer tubes off just infront of the cross over pipe .

Pic two is of the # 2 cylinder pipe marked for removal of the # 1 cylinder pipe to join it and be welded together .

Pic 3 is both head tubes side by side showing there match .

Pic 4 and test fit before bolting up to the bike for a few tack welds. The removal for the final weld out .

Pic 5 the header finshed and ready for fitment of the midpipe and can

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Pic 6 is the back of the header welded out .

Pic 7 test fiting the mid pipe and can

Pic 8 System complete and ready for some high heat paint and bolt up.

Pic 9 close up mounted on the bike .

Pic 10 the 500 is a bit lighter now and has a nicer look IMO .

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Pic 11 making the can flow a little better by removing the baffle .

Pic 12 making use of my tire machine to knock out the inner screen and break lose the baffle I just drilled lose for final removal .

Pic 13 baffle removed .

Pic 14 left side pic

Pic 15 Rear view pic .


Amber my wife is very happy and so am I since I saved $300 on buying a full system . Next I need to paint the front fairing for her.
Something with a custom look .

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NICE!! I was wandering when someone would do their own exhaust.....Looks good bro...

 

I have also built severalfull systems for the ZRX 1200 and 1100 .

Thank you . Here are a few pics of a system I built for a friend using my 1200 as the template for fitment .



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Nice job c10 - great post too!

 

Nice work bro.