OK here's the exhaust (slip on) I built today. I shot a quick vid with my digital camera, sounds pretty close to the actual sound (definitely sounds better in person but sounds pretty darn good in the vid if I do say so.) I'm going to get a chrome band to use for a clamp strap, or go by the exhaust shop and have a couple mounts welded to the muffler so I don't have to use the strap. If I do the latter it will look more like stock with the exception of the tip. Comments ???

http://www.youtube.com/watch?v=sBatsBGItiE

EDIT: Now selling everything packaged together and ready to bolt on.

http://forums.kawasakiversys.com/showthread.php?t=693

OK, everybody that is going to build one or that has bought one, here's a good tip.

When you install the tip, use some Loctite on the screws to keep them from backing out. Alternately, when you get the tip in the position you want, mark the outlet of the muffler where the set screws for the tip touch, and drill holes through the muffler outlet in the same locations. Then you can run the tip mount screws all the way through into the muffler outlet. If you like, you can get some appropriate sized nuts to further strengthen the tip mount. Even if you do this, I would still recommend using Loctite to keep the screws in place.

The reason I put this here is that I've heard from a couple of guys that made their own setups that have lost tips due to the screws coming loose. I put loctite on mine when I installed my tip and it has been holding on fine. Ultimately the very best way to mount it is run the screws all the way through the muffler and put nuts on the back side, and use Loctite as well. I am leaving that decision up to you. :thumb:

Looks and sounds good.

Does it save any weight?

Looks and sounds good.

Does it save any weight?

Thanks! Yes it definitely saves weight. I'd say it weighs about 1/2 what the original exhaust did. I'm uploading some pics to show it a little closer.

Here are some pics.

http://www.********.com/Versys/exhaust/1024_P1040857.jpg

http://www.********.com/Versys/exhaust/1024_P1040859.jpg

http://www.********.com/Versys/exhaust/1024_P1040860.jpg

Thanks! Yes it definitely saves weight. I'd say it weighs about 1/2 what the original exhaust did. I'm uploading some pics to show it a little closer.

Did you get my P/M? I like the look of that tip.

Did you get my P/M? I like the look of that tip.

Sent one back. :)

Wow, you're ready for the V market, try some headpipes and you will see how she responds.

Cheers

Frank

HA!! I just read your post about this on the other forum. It sounds & looks good, but you gotta fess up the secret! Give details, like where, what, how much, does it have a cat???

Good job, by the way, it looks factory!!

HA!! I just read your post about this on the other forum. It sounds & looks good, but you gotta fess up the secret! Give details, like where, what, how much, does it have a cat???

Good job, by the way, it looks factory!!

Thanks! I was very happy with how it turned out. Hmmm, details. I figured somebody might want to know a little more about it. I will update later when I get home and I'm not typing on this miniature keyboard.

http://i59.photobucket.com/albums/g304/Bear_on_a_bicycle/lurker.gif

Looks great, Sounds great, how is the ride?

Cheers,
Colin

OK details.

The muffler is a Cherry Bomb Turbo muffler model 87701. 2" In/Out offset on both ends. It weighs 7 lb. It is 100% Mechanically locked aluminized steel. I had to cut about 3/8" off the inlet, and 1.5" off the outlet.

To mate the muffler to the stock header flange, I used an Auto Zone part number 17508 adapter that has adapts 2" ID to 1 13/16" OD. I had to file the inside of the 1 13/16" end mainly in the areas the pipe was seamed together. Once I got it filed right, the 1 13/16" end was a perfect fit to the stock header flange. The 2" end fit right over the muffler inlet no problem.

I used a 1 5/8" and a 2" exhaust clamp, no problems with those, they were a great fit. I also got some cheap exhaust hanger strap to hold it in place. I knew it was temporary so no big deal. I am either going to find some chrome strap with no holes or get my buddy at the muffler shop to weld on a couple of hangers and get rid of the strap all together.

I had bought a 2 1/4" turnout chrome tip to put on the end. I was going to cut it down and use the end piece, but the tip was the wrong size and wouldn't fit on the muffler. I dug out some aluminum tubing I used for a twin turbo project, eyeballed the angle and curve of the swingarm, and cut a tip out of an aluminum bend. I wanted the tip to pretty much follow the curve in the swingarm to make it look as good as I could.

My goal was to make it look like it came on the bike. I thought about using one of the "fart can" mufflers like a lot of the import guys use which would actually look really similar to the custom cans they are selling for bikes. I really didn't want to pay as much for one of those mufflers as what they cost though. I ended up spending about $50 and few hours time getting it all together. I want to get some stainless v-band style exhaust clamps to replace the cheap ones I used, and get rid of the cheap strap holding it up, but it sounds as good if not better than I had hoped. Excellent tone, not too loud, and didn't cost me $300-400.

More pics of the whole bike.

http://www.ayresprohomeinspection.com/Versys/exhaust/1024_P1040871.jpg

http://www.ayresprohomeinspection.com/Versys/exhaust/1024_P1040875.jpg

http://www.ayresprohomeinspection.com/Versys/exhaust/1024_P1040887.jpg

Gratuitous shots of my tank protector and front driving lights.

http://www.ayresprohomeinspection.com/Versys/exhaust/1024_P1040885.jpg

http://www.ayresprohomeinspection.com/Versys/exhaust/1024_P1040890.jpg

Nice job!! Now we're just waiting for a ride report...




Makes me wonder if a person could replace just the stock tip with something like yours, just for looks...



:interesting:

Sorry, forgot to post up about riding it. Sounds just as good on the road, not too loud, has a really deep mellow tone to it. :D

Fantastic job, an affordable alternative. Can you tell us a bit more about your auxilliary light set up? I really like how clean the install is. What parts did you use?

Thanks,
Wardo

Fantastic job, an affordable alternative. Can you tell us a bit more about your auxilliary light set up? I really like how clean the install is. What parts did you use?

Thanks,
Wardo

Thank you! The lights so far are only mounted, they are not wired up yet. I have to get a relay from the parts store, I am going to wire them up to come on when I turn on the high beams. That way I don't have to use a switch to operate them.

Thanks for the info. What brand lights are those?

Wardo

Thanks for the info. What brand lights are those?

Wardo

Those came from Wal-Mart. I think they were either $15 or $20. I liked the size and shape.

Do you have pictures of the left side of the bike? I would be curious to see what the muffler looks like from that angle, too.

How did you mount it to the bike's frame?

Your setup sounds better than nearly everything else out there IMO. The only thing I would want is a bit more weight reduction, but I think this is an excellent alternative. Thanks for sharing!

Do you have pictures of the left side of the bike? I would be curious to see what the muffler looks like from that angle, too.

How did you mount it to the bike's frame?

Your setup sounds better than nearly everything else out there IMO. The only thing I would want is a bit more weight reduction, but I think this is an excellent alternative. Thanks for sharing!

I'll try and get some tomorrow, it was raining today. I mounted it to the stock mount with a muffler strap. If you look at the pics you can see the strap pretty close to the middle of the muffler. I am going to get rid of that strap and either put a chrome one on it with no holes, or get my buddy at the exhaust shop to weld a couple of mounts on the top side of the muffler.

Bike looks great....good job:thumb:. How did you mount the driving lights? What did you use to mount them?

Bike looks great....good job:thumb:. How did you mount the driving lights? What did you use to mount them?

Thanks! I bought some long bolts that would screw into the stock fairing mount, and some steel spacers from Lowe's hardware. I ended up having to stack about 3 flat washers along with the stock plastic washer against the fairing to get the right spacing but it worked out well. I wired them up today to come on when the bike comes on (triggered off the factory daytime running lights through a Bosch style relay. The main power runs directly off the battery through it's own inline fuse.) I'll take more pics later to show how I ran the wire. I drilled some holes in each side fairing the size of my small wire loom and ran the loom/wiring all the way from the light and through the fairing. Looks factory IMHO.

Dude, that exhaust sounds awesome!!! Much better than those $250+ dollar ones. Thanks for this thread 08Versys!

Excellent! Any decell popping?

Dude, that exhaust sounds awesome!!! Much better than those $250+ dollar ones. Thanks for this thread 08Versys!

Glad you like it! I have some stainless t-bolt clamps on the way to replace the cheap muffler clamps I'm using now, and some stainless strapping on the way as well to replace the cheap muffler strap on there now. Once I get everything just how I like it, I'm hoping to package it all together and precut/prefile everything so it's easy bolt on install and sell a few on the cheap.

Excellent! Any decell popping?

Only from a high RPM, engine braking decel, and then it's not much. Otherwise under normal or even spirited riding it doesn't pop. I don't usually decel like that from high RPM's, but I did just to see if it was going to pop.

I love this kind of thing. How about performance? How has it affected the ride? I know its more for sound than anything, but any adverse affects? If not then I'm about to do my first real mod with your set up. :yeahsmile:

The performance seems the same to me. My butt dyno doesn't say I've gained any performance. I did it mainly for the sound. :D Plus it's an easy swap back to the stock can if you want to go back. It's only a few bolts.

:clap::clap::clap:

Only from a high RPM, engine braking decel, and then it's not much. Otherwise under normal or even spirited riding it doesn't pop. I don't usually decel like that from high RPM's, but I did just to see if it was going to pop.

Sweeeeet! Put me at the top of the list when they are ready. I'll take one!

Very nice job!!! I love the way it looks, and sounds darn good too, props!!! If you do throw a few together, lemme know too, I would mos def be interested!!!:yeahsmile:

Also saw your post on the other forum. Want to kow more about how you installed your driving lights and what lights did you use.

Wanted to do the same, but could not figure out how

Thanks again guys.

I'm waiting on parts to get the exhaust setup like I want it to be. I'll get it finalized with the new clamps and strap, and get an off the shelf tip picked out that looks nice and I can modify to fit right. Then I'll get more pics and some new sound clips, and start taking orders after that if anybody is intersted. I am setting up to be a "Supporting Vendor" on this site to keep it official here, even though I don't actually own a shop (this is done in my garage and mostly because I have fun doing it.) I have been customizing show and drag cars for over 25 years though so I do have a good bit of experience in what looks good, sounds good, and performs good. Check out my home page at http://www.********.com to see some examples of a few of my past projects.

Here are a few more pics from the L side of the bike, I had a few requests for these.

http://www.ayresprohomeinspection.com/Versys/cached/1024_P1040898.jpg

http://www.ayresprohomeinspection.com/Versys/cached/1024_P1040896.jpg

http://www.ayresprohomeinspection.com/Versys/cached/1024_P1040895.jpg

Also saw your post on the other forum. Want to kow more about how you installed your driving lights and what lights did you use.

Wanted to do the same, but could not figure out how

I got the driving lights from Wal-Mart in the automotive section. They are 55W oval lights and were either $15 or $20, I don't remember. I took the mounts that came on the lights off, and bought some long bolts that would screw into the stock fairing mount, and some steel spacers from Lowe's hardware to go through the molded hole in the bottom of the lights. I ended up having to stack about 3 flat washers along with the stock plastic washer against the fairing to get the right spacing but it worked out well. I wired them up to come on when the bike comes on (triggered off the factory daytime running lights through a Bosch style relay. I am thinking about moving the trigger wire to come on with the low beam instead. That way they aren't on when you 1st turn the ignition on. The main power runs directly off the battery through it's own inline fuse.) I'll take more pics later to show how I ran the wire. I drilled some holes in each side fairing the size of my small wire loom and ran the loom/wiring all the way from the light and through the fairing. Looks factory IMHO.

It goes to show the level of skill/patience I don't possess

Wow!!!:eek:
Some damn fine projects on your site, 08 V.!!! I am also a massive car/truck junkie, anything with a motor, really! I will definitely be snagging one of your custom exhausts when you start doing them, so very nice, keep us up on how to get one when you're ready!!!:thumb:
Fukken cheers,
Erik!!!

I see you have the super secret squirrel JC Whitney trunk also. I painted the orange and the cross flat black and it works great.

I see you have the super secret squirrel JC Whitney trunk also. I painted the orange and the cross flat black and it works great.

Yessir. Can't beat it for $50, and it's amazing that it fits perfect on the Givi rack too! I also plan on painting the orange strip, just not black. :) Oh and peeling the maltese cross off and sticking something else on there.

This idea is so good that I put one on my bike last night. Might have beat you to the punch with the stainless T-straps. For the mounting strap I used a stainless no hole hose clamp. Total cost: $42.58 including the Governors share. Thanks for the great idea! :clap: :clap: :clap:

This idea is so good that I put one on my bike last night. Might have beat you to the punch with the stainless T-straps. For the mounting strap I used a stainless no hole hose clamp. Total cost: $42.58 including the Governors share. Thanks for the great idea! :clap: :clap: :clap:

Awesome! What do you think about the sound ? Also, I got my clamps in today and installed them as well. :D Here's a pic of the new stainless t-bolt clamps. They look MUCH better and have a bigger clamping surface. BTW I'm about to reply to your PM.

http://www.ayresprohomeinspection.com/Versys/exhaust/1024_P1040860.jpg

The sound is exactly what I was looking for. Kind of a cross between a Duc and a big block Chevy with Flowmasters. I have the same clamps also.

:thumb::thumb:

Sign me up.. sounds just right! :clap:

This idea is so good that I put one on my bike last night. Might have beat you to the punch with the stainless T-straps. For the mounting strap I used a stainless no hole hose clamp. Total cost: $42.58 including the Governors share. Thanks for the great idea! :clap: :clap: :clap:

Can you post some pics?

08, Man you're a genuis. I had already cut up and debaffled my stock exhaust. Sounded better than stock, but still to much like a mower. I threw out the money to try a turbo muffler and it sounds awesome. Reminds me of my 65 mustang. This is the best bang for the buck and the first mod I would recommend to anyone. :thumb::thumb:

Has any body found a local store that carries the 87701 muffler? Every body wants to order it....Hell, I can order it! I want to walk in and walk out with it!

08 may have single-handedly killed the after market exhaust sales for the Versys. I was at the local advanced auto yesterday looking for one...

I found it for $28.17 shipped....

http://www.performancepeddler.com

Really nice work on the exhaust, 08 Versys. How long is your muffler body? I had all planned out to do the same thing with a Magnaflow satin finish stainlesss steel 4" round, 14 inch long straight flow muffler, available for $55... I have the straight flow 5X8, 18" Magnaflow satin stainless on my car with header/high flow exhaust, and it's remaquably quiet for a straight path muffler...
http://www.magnaflow.com/02product/shopexd.asp?zone=main&id=7405

After learning of a corroding stock header, I decided to get the entire 304 grade stainless Muzzy system for only $425 shipped, and added a baffle to the slip-on. I saved well over $2000 on a leftover 2007 Versys, after all...

Really nice work on the exhaust, 08 Versys. How long is your muffler body? I had all planned out to do the same thing with a Magnaflow satin finish stainlesss steel 4" round, 14 inch long straight flow muffler, available for $55... I have the straight flow 5X8, 18" Magnaflow satin stainless on my car with header/high flow exhaust, and it's remaquably quiet for a straight path muffler...
http://www.magnaflow.com/02product/shopexd.asp?zone=main&id=7405

After learning of a corroding stock header, I decided to get the entire 304 grade stainless Muzzy system for only $425 shipped, and added a baffle to the slip-on. I saved well over $2000 on a leftover 2007 Versys, after all...

Thanks! The muffler body is 11" on the one I used. You wouldn't be able to put anything much bigger than that in there without modding the stock header, and I wanted to keep it as stock as possible so I could bolt the stock can back on easily. I thought about a round muffler but couldn't find anything the size I wanted. This oval muffler is just 3.5" thick so it doesn't hang down either. Much thicker and you will start losing ground clearance. I'm still looking for other options just to see what will fit and sound good. I'm just extremely happy I ended up with an awesome sounding muffler on the 1st go around, and it was inexpensive to boot.

In case any one wants to know...

http://i8.photobucket.com/albums/a28/K4XA/CB87701.gif

I got mine from autozone. I just walked in told them the part number and they ordered it. Had it about noon the next day. They get it from a parts warehouse and it didn't sound like they normal stock these in the stores since it is only a 2" in/out. cost me around $28 too.

Ok 08Versys so I got the cherry bomb and adapter on order from auto zone. Where do you suggest getting the t-bolt clamps? Also, how do you have the exhaust tip mounted? Is is just snug fit, or did you tack it?
And last one, where do i get the tip material and what diameter is it?

...Where do you suggest getting the t-bolt clamps? Also, how do you have the exhaust tip mounted? Is is just snug fit, or did you tack it?
And last one, where do i get the tip material and what diameter is it?

An easy place to find the t-bolt clamps is ebay. You are probably going to need 2" and 1.75" t-bolt clamps. I say "probably" because some companies have different size ranges for the same size t-bolt clamps, you just need to watch out that they will clamp the size you need. I don't have the exact outside diameters of the fitted product, but I will use my micrometer and post that later. EDIT: Measured sizes are 2 1/16" and 1 3/4", so the clamp sizes I posted should work. Just make sure the clamps you get will clamp in that size range.

I made the tip mount like a traditional exhaust tip mount. I drilled and tapped 2 holes on the back side of the tip, and put some machine screws in that I tighten up to hold it tight.

I made mine out of a some 2.25" 90 degree aluminum bend I had left over from a previous project. You can also buy that on ebay. After looking for some more of it, it looks like those pieces have gotten expensive as of late. I'm still looking for an off the shelf exhaust tip solution I can use to sell with the kits I am putting together.

I wouldv'e fitted the 14" long 4" round Magnaflow like the available slip-ons with the end out by the rear tire, by cutting a slice out of a 2" OD pipe and welding it to desired angle... Here is a good supplier of stainless elbow tubing, etc:
http://www.acestainless.com/index.php?act=viewCat&catId=12

I wouldv'e fitted the 14" long 4" round Magnaflow like the available slip-ons with the end out by the rear tire, by cutting a slice out of a 2" OD pipe and welding it to desired angle... Here is a good supplier of stainless elbow tubing, etc:
http://www.acestainless.com/index.php?act=viewCat&catId=12

And stainless doesnt rust right?

And stainless doesnt rust right?

It doesn't rust as easily as plain steel. I'd place it one notch above aluminized steel. Galvanized steel would come in 3rd in a corrosion resistance contest.

08 Versys...:clap::thumb::clap::thumb:
Well done! I was wondering if there was a better, cheaper way as well.....I think you found it. Thanks!

My "aluminized steel" (we call it Galvalume in the refrigeration industry) Flow Masters exhaust rotted right out from under my P/U truck in no time at all (OK a couple years, I was pretty disappointed).... granted our bikes won't see nearly the abuse as a truck, all the same, I'd much rather use Stainless if I were to do the mod. I would think SS it would be a lot easier to clean up and less prone to corrosion.

Still, this is a very cool mod, especially at the price! (just griping about my experience with that material, but for $28, you could just replace it when the time comes, if ever...)

Luke

...but for $28, you could just replace it when the time comes, if ever...)

My thoughts exactly. :thumb:

OK, I've settled on my final design and parts.

Cherry Bomb 87701 muffler
Header to Muffler adapter
2 Stainless clamps for adapter
Stainless no hole muffler strap
Custom made aluminum turnout tip
Instructions

I'll package everything together ready to bolt on, and have instructions with pictures, including what size tools you need, etc. I'll precut the muffler inlet and outlet to the correct lengths, prefile the header to muffler adapter so it fits correctly, and custom make an aluminum turnout tip, and drill and tap the tip for two set screws. $135 including shipping anywhere in the 48 states, Paypal OK from confirmed addresses only, I will not ship one to you unless it's to a confirmed address on your paypal account (matches your credit card billing statement) so please don't ask me to. I will just refund your payment if you don't have a confirmed address.

If you would rather find or make your own tip, knock $20 off the total and make it $115 including shipping. Honestly I'd rather sell them without tips because the material costs so much and it would be a lot less labor, but you are going to have a hard time finding a decent tip. If I eventually find an off the shelf tip I can easily mod to work I'll quit making tips and go that route.

I'm expecting all the misc parts in to make about 10 of these by first part of next week with the exception of the mufflers. I will order the mufflers as people place orders, so expect a one week delay before I will be able to ship them once you place the order.

FYI, the parts total for this whole package comes to around $62. By the time I pay to ship them, I'm making about $50-55 each on these. No I won't sell them for less, and I won't package them any different than the 2 ways I'm offering them. I'm not trying to get rich, just trying to help the working guys like me save a few bucks and get a great looking and sounding exhaust for a reasonable price. I've already told you how you can build your own, this is the next step for those that don't want to fool with finding, ordering, cutting, filing, etc.

Here are a few new pics with the new stainless strap.

http://www.ayresprohomeinspection.com/Versys/cached/42f91a5f.jpg

http://www.ayresprohomeinspection.com/Versys/cached/8b4a4c17.jpg

http://www.ayresprohomeinspection.com/Versys/cached/ce38836e.jpg

http://www.ayresprohomeinspection.com/Versys/cached/73159fff.jpg

http://www.ayresprohomeinspection.com/Versys/cached/4d761c4d.jpg

08,
Looks great! I'm thinking about it even tho I have a Scorpion set up.
The only thing you may consider is to provide all the goodies and let everyone source the muffler on their own? Just a thought.
Thanks for the super job of research and development!!

08,
Looks great! I'm thinking about it even tho I have a Scorpion set up.
The only thing you may consider is to provide all the goodies and let everyone source the muffler on their own? Just a thought.
Thanks for the super job of research and development!!

Thanks! Yeah I was thinking about that option as well. I'll put the pen to paper and maybe make that a third option. Good suggestion. :thumb:

08,
Even without the muffler your price is a deal!!

OK now there is a third and fourth option due to popular demand (2 suggestions already.) Options 3 and 4 you buy your own muffler and cut the ends to fit.

3rd - Same as option one, minus the muffler = $95 shipped.

4th - Same as option two, minus muffler and minus the custom tip = $75 shipped

08 Versys,
That's an awesome deal.....I'm gonna have to wait a couple of months because I just bought the hugger and my fork & swingarm sliders and am working on frame sliders this month. Gotta give my wife some time to cool down.......Bought the bike 1 month ago and spent another $1K on my riding gear.......Getting YOUR full exhaust setup is my goal for September.

Thanks for the research and development for us guys that don't want to spend $300-$600 for an overpriced rattletube......I prefer an American-made muscle-packed Cherry Bomb to a Yoshimura any day of the week!

I have emailed install instructions (in Word .doc and Adobe .pdf form) to everyone that has paid for their exhaust so far. I am going to upload the files somewhere so I can just provide a link to them in the future, and it will always be the latest copy available. FYI, the files are about 2.5MB each. If you buy a setup, let me know if you prefer .doc or .pdf and I can make the email I send you smaller. :thumb:

OK direct download links for those that want to check them out. Please let me know what you think. I'm no technical writer, but I've seen much worse when it comes to instructions. Critiques, comments, and suggestions welcome!

Word .doc
Gigasize link
http://www.gigasize.com/get.php?d=5c6fkd3k9qb

Rapidshare link
http://rapidshare.com/files/131175394/Kawasaki_Versys_Custom_Exhaust_Instructions.doc.ht ml


Adobe .pdf
Gigasize link
http://www.gigasize.com/get.php?d=kr1bccglcdb

Rapidshare link
http://rapidshare.com/files/131175395/Kawasaki_Versys_Custom_Exhaust_Instructions.pdf.ht ml

I want just the turn out.....how much??

I want just the turn out.....how much??

Oh dang, sorry I forgot about that. I'll definitely let you know tonight.

By the way, nice driving lights. Where did you get them,how much were they, and how well do they work? :clap:

Oh dang, sorry I forgot about that. I'll definitely let you know tonight.

Cool beans!

By the way, nice driving lights. Where did you get them,how much were they, and how well do they work? :clap:

Yes they definitely work well. :D Check out this post I just made.

http://forums.kawasakiversys.com/showthread.php?t=747
.
.
.

08V, Can you send me just the t-bolt clamps, muffler strap, and aluminum tip w/screws? If so, how much w/shipping?

08V, Can you send me just the t-bolt clamps, muffler strap, and aluminum tip w/screws? If so, how much w/shipping?

Sent you a PM.

Pm'd you back.

OK direct download links for those that want to check them out. Please let me know what you think. I'm no technical writer, but I've seen much worse when it comes to instructions. Critiques, comments, and suggestions welcome!

Word .doc
Gigasize link
http://www.gigasize.com/get.php?d=mkz68dgk16b

Rapidshare link
http://rapidshare.com/files/129024333/Kawasaki_Versys_Custom_Exhaust_Instructions.doc.ht ml


Adobe .pdf
Gigasize link
http://www.gigasize.com/get.php?d=rdhbxmh7pwb

Rapidshare link
http://rapidshare.com/files/129024334/Kawasaki_Versys_Custom_Exhaust_Instructions.pdf.ht ml


Daayum 08V yur a pro! :clap: Awesome instructions! Only thing you left out is the beer for afterwards.

NO BEER :eek: Thats it I quit this stinkin place.



















Oh after a few BEERS I feel better now. Please go about your bussiness. :D

Payment sent for the turn out. Thanks!

The delivery people were kind to me today, got a lot of the parts in for the 1st batch of kits. :D Hopefully the rest of it arrives tomorrow and/or Wednesday and I can get all the work done and ship all that have been paid for on Thursday. :thumb: :thumb:

http://www.ayresprohomeinspection.com/Versys/cached/bf3c81ad.jpg

http://www.ayresprohomeinspection.com/Versys/cached/58eeb42f.jpg

http://www.ayresprohomeinspection.com/Versys/cached/2bf144c6.jpg
.
.

OK the first batch is going out today. I was sent the wrong size small stainless clamps and am getting the correct ones today. I'm about to make shipping labels and will be taping up boxes later today when the correct clamps arrive. I can't wait for you guys to install them and hear what they sound like in person. :D

:yeahsmile:OK the first batch is going out today. I was sent the wrong size small stainless clamps and am getting the correct ones today. I'm about to make shipping labels and will be taping up boxes later today when the correct clamps arrive. I can't wait for you guys to install them and hear what they sound like in person. :D

ROCK AND ROLL!!!:yeahsmile::yeahsmile::yeahsmile:

OK, everybody that is going to build one or that has bought one, here's a good tip.

When you install the tip, use some Loctite on the screws to keep them from backing out. Alternately, when you get the tip in the position you want, mark the outlet of the muffler where the set screws for the tip touch, and drill holes through the muffler outlet in the same locations. Then you can run the tip mount screws all the way through into the muffler outlet. Even if you do this, I would still recommend using Loctite to keep the screws in place.

The reason I put this here is that I've heard from a couple of guys that made their own setups that have lost tips due to the screws coming loose. I put loctite on mine when I installed my tip and it has been holding on fine. Ultimately the very best way to mount it is run the screws all the way through the muffler and put nuts on the back side, and use Loctite as well. I am leaving that decision up to you. :thumb:

OK, in light of Hooligan's problem with his header, here are my thoughts and a few comments from others.

I disassembled my exhaust today to see how sturdy the mount was using the stainless strap the way I have it routed. Honestly I don't think anyone will have any problems mounting it the way I have shown in my instructions. I do think it will be a good idea to get a thin piece of rubber or exhaust gasket material made for holding up to exhaust heat, and placing a thin strip in between the muffler and frame mount (I believe I noted that in my instructions as an option) just to prevent any squeaks or rubbing from occurring. On my setup I can see very small evidence of the muffler rubbing against the frame bracket where it is contacting it. The gasket material would provide a cushion and prevent metal to metal contact at that point. That could prevent a rub-through in that area in the distant future.

There have been others that say the best way to mount it would be to mimic the factory mount setup, and have a bracket welded to the muffler and hang it from the factory frame mount. That is an excellent idea as well. Being as I don't have a production facility capable of welding and duplicating that kind of setup, I am not doing it that way. I'm sure you could hit up your local exhaust shop and have them weld on a bracket and mount it to the factory locations for a small amount of $$$ if you would feel more comfortable doing it that way. Personally I am keeping the stainless strap setup on mine, mounted the same way I am shipping them out to people that buy a setup. Some say the strap detracts from the looks of the setup, personally I like it.

Also, anyone that has bought a system so far, please download the latest copy of the instructions. I have made an important note in light of what a few people have told me about the systems they put together on their own, notably about mounting the exhaust tip. I have over 400 miles on mine just using the set screws with Loctite (not drilling holes in the muffler outlet) and it has been rock solid. I have had reports from a few people that made their own systems, and lost several tips. I am assuming this is from the screws backing out. That is why I am making the following recommendation.

If you want the very best, most solid mount of your tip with almost zero chance of it falling off do this. Drill holes through the muffler outlet pipe in the locations I have put the set screws on the tip, and put a nut on the backside of that, and use Loctite when assembling it.

After I disassembled my system today to check it all out, I remounted my tip by drilling like I described above and using a nut and Loctite. I can say it's definitely about as solid as you can get, and I only drilled one hole where the bottom most set screw hole is located.

I would pre-drill a hole in the muffler, but I know everyone will most likely want their tip rotated a different way, so I'll leave it up to you to decide how you want the tip oriented and what method you choose to mount it. Please don't come to me after you install it and complain "My tip fell off, can you send me a new one for free." I sold a couple of tips way cheaper than I should have, they are not easy to make and take up a lot time. The more I make the better I am getting at making them and the quicker I get, but they are labor intensive. Any requests for tips only in the future will cost $50 including shipping in the 48 states. I know it's expensive, but I spend a lot of time making them. I guess that's the main reason I'm adding all this and making sure everyone mounts their tips in a way they are comfortable with. If you lose it, it won't be cheap to replace, so mount it like it's gold. :D
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For the exhaust tip, I was thinking some ULTRA COPPER RTV and some Rivets on the backside. That way it is sealed, and has a good mechanical mount as well as the adhesive.

On the inlet side I was thinking of leaving the factory Gasket, and using the next size up adapter. That way it will isolate some of the vibration from the header.

Todd

For the exhaust tip, I was thinking some ULTRA COPPER RTV and some Rivets on the backside. That way it is sealed, and has a good mechanical mount as well as the adhesive.

On the inlet side I was thinking of leaving the factory Gasket, and using the next size up adapter. That way it will isolate some of the vibration from the header.

Todd

Excellent idea on the rivets for the tip! You don't need any RTV on it, sealing the tip won't do any good, the exhaust is already exiting the muffler at that point, and it is inside the tip.

Using the factory header gasket is also an excellent idea. You will have to order a new one from Kawasaki if you want to do that. The stock gasket is stuck inside the stock muffler with some kind of adhesive. There is no way to get it out without tearing it up.

Excellent idea on the rivets for the tip! You don't need any RTV on it, sealing the tip won't do any good, the exhaust is already exiting the muffler at that point, and it is inside the tip.

Using the factory header gasket is also an excellent idea. You will have to order a new one from Kawasaki if you want to do that. The stock gasket is stuck inside the stock muffler with some kind of adhesive. There is no way to get it out without tearing it up.


I was thinking the Silicone might help dampen the tip a little from vibration since it is hanging out there a bit. As well as sealing and Holding the tip in place if the Rivets came loose. As far as that goes you could probably silicone the tip on, and it would be fine forever. The Rivets would just add a little security, in the event the tip worked its way loose.

I was able to get my OEM gasket off with out damage, just had to be patient and work a dental pick between the two.

Todd

...I was able to get my OEM gasket off with out damage, just had to be patient and work a dental pick between the two.

Todd

Outstanding. I tried the dental pick method as well and was unsuccessful. Mine appeared to be almost "glued in" with some kind of high strength adhesive. I only succeeded in scratching my gasket up. If I ever put the stock muffler back on I'll have to get a new gasket.

Got my tip yesterday 08V. What a beautiful piece of work. Well done mate.

Thanks bro! A lotta love and sweat goes into those. :cool: :thanx:

It's well worth it! I put the stock muffler back on, but I'm trying to figure a way to use your turn out on it.

Received my tip today and stuck it right on. The UPS guy could not get here fast enough. After farting around trying to make my own tip and losing it a couple of times. I decided to go with 08's custom tip. It is easy to work with and looks great. I did not want to loose this one so I fastened with some some metal stud screws. I also popped a couple of screws through the muffler strap in the muffler. Everything seems pretty secure from my short boot around the neighbourhood and the sound is awesome.


Cheers,
Colin

Got my kit a few days ago, went ahead and painted the adapter and muffler BBQ black to maybe ward off future rust a little. Actually looks great with the stainless strap, clamps, and tip. Sound is outstanding!

nice setup and sound
sounds like my son's 250 ninja with a muzzy exhaust, only the muzzy is alot louder

Got my kit a few days ago, went ahead and painted the adapter and muffler BBQ black to maybe ward off future rust a little. Actually looks great with the stainless strap, clamps, and tip. Sound is outstanding!

Can you post some pics?

Got my kit a few days ago, went ahead and painted the adapter and muffler BBQ black to maybe ward off future rust a little. Actually looks great with the stainless strap, clamps, and tip. Sound is outstanding!

:thumb: :thumb:

We need pics!
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I'll try and take a couple later this evening

how does the bike feel power wise now, any increase you can feel or just sound?

Excuse the dirt... rained on me during my commute home. Pic quality is also a little weak, as it is overcast and about to rain some more...

I didn't notice any power, but I'm not a speed demon and don't use half of what is available anyway, so someone else my notice an increase... but the exhaust sound is sweet. At first, I though I'd made a mistake, as it is louder than I expected. The reality is that the stock is very, very quiet. I almost took it off the first day, but decided to stick it out and put some miles on it. I now have about 4 days commute on it, and it has grown on me quite a bit. The cherry bomb has a nice, deep, throaty sound down low, and is fairly quiet at cruise... It's a keeper!

The first time I rode it, I had just put my Givi shield on, and may have been getting too much reflection off the shield for my taste. The Givi blocks too much wind for the hot summer months, so I put the stocker back on. The Givi will come back out once the weather starts to cool.

OK, Pics of a black cherry bomb....... and my guard dog.. they both have a growl that will get you attention!!

That looks pretty good! Nice dog...


German Shepard mix?

Great write up.............since I don't have a Versys yet; I do have a much modified '99 KLR and a stock '06 KLR. The muffler would work great on the motarded '99. Just need a custom header, that's easy enough through friends.

A Versys in '09, would be fine!

Not mix.. full blood German Shepherd.. lineage is heavy on East German lines.. He's still all puppy (10 months), so he has about 1.5 more years of filling out to do :eek: He was the runt of the litte and is actually on the small side at around 50lbs. He should be about 75-85 lbs when he finishes growing.

I was pleased how the BBQ black turned out. When I first painted it, it dried to a very dark gray, but has since cured to a semi-gloss black.


That looks pretty good! Nice dog...


German Shepard mix?

That is one feeerocious lookin beast! Good looking bike and great looking dog!

I would like to know how much does it cost to put the V on a dyno now that you have done the muffler. The weight is not that big of a deal put every little bit of power helps. I think you did an awesome job!! I say A++ for looks and price. Keep the awesome ideas flowing.

Thanks bro! It's going to cost me $200 for the dyno time, because I will be getting a baseline done (with my slip-on and stock computer tuning), then getting a custom tune done with a Power Commander III (another $265-$275.)

Ninja 650 kit fitted today. :D It's almost identical to the Versys kit. Only difference was a bracket I had to add to drop the muffler down about an inch off the stock muffler frame mount. The Ninja kit will be $10 more than the Versys kit due to having to make the extra bracket.

http://www.youtube.com/watch?v=0SivKhIqptU

http://ayresprohomeinspection.com/Versys/exhaust/install/Ninja_650/Ninja_650_finished.jpg

http://ayresprohomeinspection.com/Versys/exhaust/install/Ninja_650/Ninja_650_finished_3.jpg

http://ayresprohomeinspection.com/Versys/exhaust/install/Ninja_650/Ninja_650_finished_4.jpg
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Hi guys. I just built one of 08Versys' systems with exception of not doing the stainless turn out yet - so the exhaust is just running straight out the muffler. My issue is there is a weird resonating sound that bounces off everything when I come to a stop. It feels like it is ringing in my head and you still hear it slightly when riding (but really bad at a stop). Is this normal or could not having the turn out cause this (i would not think so, though). I think I may just have 08Versys make one for me - but any ideas on the sound?
Thanks -

Sounds like something may not be installed just right. Even when I have run mine (and a couple of others I have installed) with no tip on them there is no resonance.

Any idea what could be different? There is not too much going on with this install to vary from one job to another. Only difference I had with my system was that I had to cut my exhaust adapter about 1/3 inch shorter. With it's stock length the muffler case would almost touch the tire (and I did cut the muffler inlet and outlets as you did). Other than that, I think it is the same.

What kind of strap do you have holding the muffler, and where is it mounted?

I have the same strap you originally had with the holes mounted through the back hole the original muffler used. I did take out the rubber gromet since I did not have room for the strap to go through with out cutting the gromet. I am going to try to find a strap like you have. Would a home depot have something like that? Would the rubber gromet not being there stir up some extra sound?

...Would the rubber gromet not being there stir up some extra sound?

Yes I think that is a very good possibility. I imagine the way yours is strapped in is causing some resonance.

Neither Home Depot or Lowes have the strap I use. I looked at both. You should be able to get one from a store that specializes in underground sewage pipes.

I think it is more a result of how sensitive you are to certain sounds. I have noticed the same sound.. it is actually less a sound.. and more a ringing in your skull (not really a ring..but a sound pulse). I get it even with earplugs. I usually wear Skull Candy ear buds and listen to music at a low volume when I ride, and that masks it quite well.

I installed my kit and a Givi screen at the same time, and at first I figured the larger screen was reflecting a lot of sound back at me.. which is probably true, but the stock screen does it as well.

So with with or without earplugs, I too get a sound pulse that seems to reside just behind my eyes, especially when stopped at a light... BUT, I don't notice it when using ear-canal headphones and my mp3 player with just enough volume to hear the music. So I don't think it is your install.. I think it is just a characteristic of the setup, and I bet it is only an issue to a few of us who are sensitive to whatever frequency the pulse inhabits.


PS. I have about a half inch of rubber between the cherrybomb and the stock exhaust mount on the bottom of the frame and am using a kit provided by V '08

come to think of it, I was getting the same sound before I bolted the support strap to the muffler. I have not heard anyhing since.

Cheers,
Colin

I had bought a Turbo Tuned Performance Muffler part number 19803 and I had it welded with a stainless steel tip. It was also fitted with a muffler hanger so there is no visable strap. I am really impressed with the low end power. I am able to wheelie at 5500 revs and I am at 6200 feet elivation. Here are some pictures of the muffler and hanger and the whole bike I dont know how to post videos to Youtube or I would post a sound clip.

Here are some mo pics.

The whole thing cost me 38 dollars for the muffler and 40 dollars to have the custom welding. Discount Muffler Works in Colorado Springs gave me the hook up. I love the sound the PRICE and the POWER!!! the Cherry Bomb is the same muffler the one I bought is made by the same company just under a different name its the same dimensions I cant spell! Well let me know if you all have any questions. I ordered the DNA air filter so I will put that in and take pictures. I am also doing the air sensor T so both throttle bodies are on the sensor. Does any one know the power commander maps for the air filter and the CUSTOM can? I love mods!!

...Does any one know the power commander maps for the air filter and the CUSTOM can? I love mods!!

Right now I am running the map for an Akrapovic slip-on muffler with aftermarket or stock filter. I also have the DNA filter. The Power Commander makes it feel like a whole new bike. It runs smoother now than it did when it was stock. :thumb: :thumb:

I plan on getting a dyno tune sometime in the next couple of months, so I'll have a custom map for the turbo exhaust setup and DNA filter soon.
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I'm looking for an extension for my front fender. Tell me about yours

It has been brought to my attention that in some cases, the muffler might be closer to the tire than mine is (I have 1" clearance between the muffler and rear tire.) The person that found this out brought up the fact that it might be due to the chain adjustment, which on a newer bike or chain could have the tire in a more forward position than mine is, therefore have less clearance between the muffler and tire.

If you have bought a muffler kit from me and you don't think you have enough clearance between the muffler and tire, and it is adjusted as far forward as you can get it, send me a PM on here or email me and let me know. You can get some money back for your trouble! 1/2" of clearance should be more than adequate.

You can

1) Cut some length from the adapter pipe to move the muffler forward some (I would recommend cutting no more than 1/2" off of it, you have to watch the clearance of the muffler as you move it forward.) When I get some time I'll see what the maximum is you should be able to safely cut.

2) Send me the adapter pipe and I will cut it for you if you don't have the means to do it yourself. In that case let me know how much clearance you had so I can cut it correctly.

If this needs done to yours, and you send me a few good pictures of the assembly showing the adapter pipe and muffler installed, the clearance between the muffler and the tire, AND a picture of the markers on your rear swingarm used for chain adjustment (showing yours as it currently is), I will refund you $10 of your purchase price. This is even if you cut the adapter pipe yourself.

I'm looking for an extension for my front fender. Tell me about yours

Sending you a Private Message.

Finally got exhaust on. Have been too busy so had dealer install with service and heated grips. I did not realize what a change this would make to character of bike. I think mechanic played with throttle and tuned as well. This exhaust was a great value and outstanding complement to a very good motorcycle. Mechanic did have to fabricate L bar to hold can in position. I am glad I had them install. The heated grips are perfect for our NW weather. The next mod is the Avon Distanzia tires which have been back ordered for 6 months. If Continental made the TKC80 for the front tire I would not hesitate to go in that direction. Hands down....OUTSTANDING MOTORCYCLE !

Does anyone have a good parts list to make this build?

Nevermind. For some reason I wasn't seeing post #12.

I have this installed now with no turn-out. The sound is great and I don't see any issues with no turn-out other than looks. Super cheap easy solution.

im up in canada do you have the part numbers for the muffler and the tip thanks rob

im up in canada do you have the part numbers for the muffler and the tip thanks rob

Just picked one up today. It's the same part number at our NAPA's as the American AutoZone's. #87701 Cherry Bomb Turbo.

Edit: I thought I would just say a big thanks to 08Versys and add a couple of picks. Tonnes of clearance and the sound is oh-so-sweet.:clap:

Anyone having any issues with the bike leaning out with this one? Or any goofy running issues with it installed?

08 Versys, you still selling these?

Can someone tell me where they found the stainless muffler strap? I have been trying to find something and haven't had any luck yet.

o8 R u still making these

You can easily make it yourself. Heres what it sounds like on the move.
http://s41.photobucket.com/albums/e264/antman325/?action=view&current=CherryBomb005.flv

Can anyone help with the "leaning out" question? Just woundering as I only have 300km on my V as of yet but I am itching for some sound. Looking to have the pipe ready for 1000km install if it works okay.

Sorry for the second post but thanks Antman for posting the vid. Hearing it under load made me want this mod even more.

I posted this back somewhere but here goes again. It will lean out 2800 to 3500 RPM. That is typically the range when in city traffic. Not long after the DIY exhaust I installled a PCIII and loaded the Akropovic map. Runs great, very smooth, no more problems......well just one, HOLD ON TIGHTER :thumb: There is a thread started about use and settings for the PCIII. Good Luck Dr.

08Versys sold or traded his V, and hasn't been on the board in a long time.

I posted this back somewhere but here goes again. It will lean out 2800 to 3500 RPM. That is typically the range when in city traffic. Not long after the DIY exhaust I installled a PCIII and loaded the Akropovic map. Runs great, very smooth, no more problems......well just one, HOLD ON TIGHTER :thumb: There is a thread started about use and settings for the PCIII. Good Luck Dr.

How does (did?) people's bikes run with just the new exhaust without any other mods (like the PCIII)? I'd like to put this on, but don't want to have to do a bunch more to adjust for the new exhaust. It's not that I'm cheap or lazy, it's just that I'm, well, lazy and cheap. :huh:

It runs just the same as stock, only with sound. The engine braking sound is actually louder than the throttle sound with this exhaust. That takes some getting used to. I'm sure you have heard sputtering or popping off idle with your bike from time to time. Bike will still do this with new exhaust. And under full load to redline, you may get a decel pop every now and again. These are the "problems" the PCIII will clean up for you as well as improve all around performance. Even if your bike is totally stock with stock exhaust a PCIII will make a huge improvement. But without the PCIII, the cherry bomb exahust works and sounds great. It's a bolt on and go deal. Just takes some getting used to after the silence of the stocker. That's my review. Hope it helps Doc. :thumb:

It runs just the same as stock, only with sound. .... That's my review. Hope it helps Doc. :thumb:


Thanks for the review and it sure helps. I've ordered my Cherry Bomb and am looking forward to puting it on. (Wish we had a "smiley" with the guy rubbing his hands in glee)

Without 08Versys' turnout, what have other folks been using for the tip?

Not sure. I have one of 08's turn outs.

Got my exhaust done a few weeks ago and thought it would be a good time to share. I used a thrush turbo (very similar to cherry bombs dimensions) and overall I'm pleased. Did not have to spend tons of money and the bike feels and sounds more powerful.

$28 for the muffler
$1.60 for the strap
$2.70 for the adapter
$1.70 for the clamp
$.68 for nylon spacer (used to avoid muffler to lower plastic contact.
$15 for merlins muffler to weld the adapter on and cut the tail piece

Total $50 for a much better experience over stock. As you can see from the pics I forgone the tail piece and left it straight. I think the look is more aggressive compared to the custom tail piece

Almost forgot. The autozone adapter will not fit on this muffler due to both having the same outer diameter of 2 inches. That's why I had the muffler shop weld it on but I'm glad I went that route. Only one clamp which means a more reliable connection and the weld job looks very nice and secure.

edit

I could be wrong, but I'm not sure a Jardin GP1 qualifies as a "custom built exhaust". Unless you bought it at Auto Zone, you need to take your ready made $300.00+ slip-on to the right thread! This thread is for those of us who are Jardin GP1-challenged. :p

I screwed up and posted this in the wrong place, sorry

I could be wrong, but I'm not sure a Jardin GP1 qualifies as a "custom built exhaust". Unless you bought it at Auto Zone, you need to take your ready made $300.00+ slip-on to the right thread! This thread is for those of us who are Jardin GP1-challenged. :p

Not sure if your referring to me. I got the muffler from napa auto parts for $28 dollars.

Unless you bought it at Auto Zone, you need to take your ready made $300.00+ slip-on to the right thread!

Just an FYI, the Jardine is only $189. ;)

Not sure if your referring to me. I got the muffler from napa auto parts for $28 dollars.

No I was referring to Jhedges although I was just jerking his chain. Sorry if I traumatized anyone.

Sorry if I traumatized anyone.

You’re stepping on the medias toes and their hype over the pig flu. Its their job to try and traumatize. :D

:exactly:

Got my exhaust done a few weeks ago and thought it would be a good time to share. I used a thrush turbo (very similar to cherry bombs dimensions) and overall I'm pleased. Did not have to spend tons of money and the bike feels and sounds more powerful.

$28 for the muffler
$1.60 for the strap
$2.70 for the adapter
$1.70 for the clamp
$.68 for nylon spacer (used to avoid muffler to lower plastic contact.
$15 for merlins muffler to weld the adapter on and cut the tail piece

Total $50 for a much better experience over stock. As you can see from the pics I forgone the tail piece and left it straight. I think the look is more aggressive compared to the custom tail piece

Almost forgot. The autozone adapter will not fit on this muffler due to both having the same outer diameter of 2 inches. That's why I had the muffler shop weld it on but I'm glad I went that route. Only one clamp which means a more reliable connection and the weld job looks very nice and secure.

Nice install!
For the Thrush Turbo muffler - Does the fuel injection system need to be reprogramed to avoid running overly lean? How much of a power increase do you think your getting? Does the mpg decrease or ? Thanks.

Just installed my custom Turbo Cherry Bomb! Sounds Great and seems like I can Catwalk a little easier! Not sure, but sure has that deep rumble and sounds awesome!!! I didn't want to use the strap so I built a bracket and welded it to the muffler. I'm very happy with my decision. Switzer Automotive in Lethbridge had a lot of great ideas and help.


Very Satisfied!

Nice install!
For the Thrush Turbo muffler - Does the fuel injection system need to be reprogramed to avoid running overly lean? How much of a power increase do you think your getting? Does the mpg decrease or ? Thanks.

I do have popping on decel but I believe it's related to the pair/air injection system. From what I've seen on the forum the pair valve injects air into the cat/muffler to help protect it on deceleration. If your using a aftermarket exhaust a few people here recommend disabling the system. Trying to find time to get to it. Yesterday I spent time doing my rim tape and today I was planning my horn install .
But back to your other question. I really do not see a power increase other than the more powerful sound the exhaust makes. Since I only have 600 miles on her I'm still trying to keep it under 6k rpm. As for mpg I've been keeping the rpm's higher then normal just to hear the exhaust. So in essence my mpg's are down only because I wanted to show off :clap:

Guys:goodidea:

Great thread on homemade system - I had the cat cut out on my ER-6f (650R) and it is a bit better note, but I would prefer a louder/ deeper note still.

Is there anything special about your "turbo" car mufflers or do you feel i could use a similar sized reverse flow sport muffler sourced here in Australia?

Redbeard

Update on my setup. Painted my Cherry Bomb with some high temp engine enamel and used some 1 inch aluminium strapping to secure. I also built my own baffle that works like a charm. It's just a piece of connecting pipe (galvanized) from the fence section of Home depot. Drilled some holes and wrapped with fibreglass. I also had to flare out the back end and taper in the front. No more popping and a little quieter without loosing the tone. I'm going to try and post up a video to YouTube later with the sound. The last picture is of my first attempt at a baffle. No fibreglass just a neck down. Worked ok, no popping but just not what I was looking for sound wise.

Here's what she sounds like.

http://www.youtube.com/watch?v=cDvw7fD5Fws

I have just signed up with the forum after Googling Versys exhaust. I have thought a bit
about the same idea, but had not gone ahead with it. One user replied that he wanted a bit more weight reduction. I do not see this is possible. I do wonder though if just using a Cheery bomb Glass pack would work. Like I said, I do not even have the dimensions of what I would need and would fit under my bike. Cherry Bomb makes a 12in glass pack I think would work with a couple small easy mods. What do you think?

I have had the cherry bomb for about 500 miles. it sounds really good to me. i don't hear a normal backfire but one loud boom usually one or two times per ride. (2 hours or so) it seems to happen when i let off the throttle at 40 - 50 mph and it really scares the hell out of me. i think it might blow off one day and hit the back tire. i need to put some screws in the connections.
i also noticed adding any tip seems to make it more quiet. anybody find a off the rack curved tip?

I just purchased the Cherry Bomb Turbo muffler at Napa today. It appears that there is no designated inlet and outlet so it can be mounted either way. The part that's confusing is that the OD of the pipes are different. Which end do most of you use as the inlet?
As for the stainless turn out, has anyone found another source now that "08 Versys" has gone AWOL?

Last weekend I installed this exhaust with the CB Turbo. Man is that sweet! :clap: It sounds perfect for me. Just a bit louder and a lot more rumble than the stock. And you can't beat the price. I had to do a bit more cutting than was noted here. I cut 1 inch off each pipe of the muffler and 1 inch off each side of the adapter. This gives me more room between the muffler and the rear tire. I love it.

Re: the two different sizes on the muffler - I know the box said both sides are the same size, but they're not. I put the smaller pipe forward since the larger one didn't fit on the adapter listed. Cherry Bomb says it doesn't matter which end is intake and which is output so I just went with the parts listed on this site.

So stick it on the bike - I know you'll like it. :cheers:

Hey Doc, thanks for respondonding. I decided to use the smaller end of the muffler for the inlet also. My local muffler shop just took a stock piece of pipe about 3" long and expanded one end to fit inside the inlet on the muffler and expanded the other end to fit over the header pipe. I then positioned the muffler with the adapter on the bike without clamps just to check clearances. Because the adapter slides inside the muffler inlet I could move it in and out to find the best position and length. I plan to go back to the shop to have them run a bead of weld around the inlet to fix the adapter to the inlet pipe on the muffler. The other end will be clamped onto the header. This eliminates a clamp and makes it easy to remove if I want to change the muffler. I never liked the idea of strapping the can to the bike so I decided to take a piece of thin cardboard, like a cereal box weight, and make a template for a bracket that the shop can weld onto the muffler. That way I can use the stock isolated mounting holes and it will look totally factory issue. The biggest problem is the outlet tip. I prefer a stainless but I'm running into problems finding such an item. The stock outlet on the can right now is almost touching the back tire. Whatever I wind up doing I will need to cut atleast an inch off just for clearance. Does anyone out there who has successfully installed the Cherry Bomb muffler have a solution for the outlet tip? I sure wish old "08 Versys" was still around. I've sent him PM's and emails but no response. I need some help here gang.

I tried to get the muffler to fit on tonight, but I simply could not get it to squeeze over the flange. That was after cutting off the suggested lengths off the muffler, and cutting 3/8" off the adapter. I guess I'll just have to cut more off tomorrow!

OK here's the exhaust (slip on) I built today. I shot a quick vid with my digital camera, sounds pretty close to the actual sound (definitely sounds better in person but sounds pretty darn good in the vid if I do say so.) I'm going to get a chrome band to use for a clamp strap, or go by the exhaust shop and have a couple mounts welded to the muffler so I don't have to use the strap. If I do the latter it will look more like stock with the exception of the tip. Comments ???

http://www.youtube.com/watch?v=sBatsBGItiE

EDIT: Now selling everything packaged together and ready to bolt on.

http://forums.kawasakiversys.com/showthread.php?t=693

OK, everybody that is going to build one or that has bought one, here's a good tip.

When you install the tip, use some Loctite on the screws to keep them from backing out. Alternately, when you get the tip in the position you want, mark the outlet of the muffler where the set screws for the tip touch, and drill holes through the muffler outlet in the same locations. Then you can run the tip mount screws all the way through into the muffler outlet. If you like, you can get some appropriate sized nuts to further strengthen the tip mount. Even if you do this, I would still recommend using Loctite to keep the screws in place.

The reason I put this here is that I've heard from a couple of guys that made their own setups that have lost tips due to the screws coming loose. I put loctite on mine when I installed my tip and it has been holding on fine. Ultimately the very best way to mount it is run the screws all the way through the muffler and put nuts on the back side, and use Loctite as well. I am leaving that decision up to you. :thumb:

Hi 08 Versys, are you still making these for sale? What price? Will it fit the 09 versys? Thanks! I am really interested in getting one.

FYI.

08 Versys sold his bike and is no longer on the forum

I tried one of his kits and wasn't impressed (didn't seem safe at all to me). 08 was kind of a dick when I returned it and did not offer a full refund either.


You'll have better results DIY if you're into this exhaust, imho. I think having somebody weld a bracket to fit the OE mount is the way to go. That hose clamp setup is just a disaster waiting to happen.

I've now had the CB exhaust on the bike for just under 1000 miles and I am loving it. I have it strapped on for now and plan to have a mounting plate like the OEM welded on when I can. the problem with that is I'll have to stop riding it for a couple of days and don't want to do that now.

Interestingly, between the new exhaust and the 16 tooth front sprocket, my milage has increased wonderfully. I got over 60 mpg on my last tank full. The tank before that was ridden especially hard and I still got 55. Before these two changes I was getting 50 mpg. and I might be kidding myself, but I think it has more mid-range power.

FYI, I have been using this exhaust for about 2k miles. Today I notice that the slip-on had cracked the main exhaust where it connects. It sounded rough so I started inspecting and there it was. In the winter the salt and what not caused the strap to corrode and break. This must have stressed that metal. I of course immediately replaced the strap, but I guess over time it still weakened even more. Now the Versys has to sit until I can get it welded back up or replace the full system. Good times.

I bit my tongue for a long time because I didn't want to cause any bad blood. I think it's great that so many people like the cherry bomb exhaust. My opinion of 08's kit however is that it was poorly designed and unsafe. The guys who have had a bracket welded are on the right track.

I returned my kit to 08 because there is no way in hell I wanted to be liable for reselling it, that's how bad I think it was. He refunded only 1/2 the purchase price. I thought I was doing the guy a favor by pointing out some problems and offering suggestions. Oh well.

I ponied up the $$$$ for a TBR setup and couldn't be happier. This is one of those cases where I think it might be better to cough the dough up for something better the first time, unless I guess you like the Cherry Bomb and are willing to take it to a shop for some custom fabrication.

I have to say if something goes wrong down there you are screwed. Luckily I noticed it before I took off. I doubt it would have fell off, but if it did you would be toast.

Myself and a friend got this working. We ended up cutting the adapter a lot more, as well as welding the adapter to the exhaust can, and fabing up a real hanger. So far it's not too bad. I still have a few clearance issues, but they are minor. And I need to replace that crap exhaust clamp with a t-bolt.