How to convert 03-05 to 06+ R6r exhaust - Yamaha R6 Forum: YZF-R6 Forums
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post #1 of 578 (permalink) Old 08-10-2008, 02:22 PM Thread Starter
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How to convert 03-05 to 06+ R6r exhaust

**First let me say, some of the pictures are courtesy of cafercr35 from sportbikes.net.**







1) First things first.

You need a muffler from a 06 and up R6r



2) Prepping the new muffler

You need to cut 2 and 7/8 inches off. The part with the exup/butterfly flap is what needs to come off. Start measuring from the lip.



Dispose of the exup/butterfly flap piece.



Next I cut off the hanger on the muffler as well. To me it wasn't a huge problem with it not being the cleanest cut, because it is hidden, and the cut will not be visible.



3) Prepping the bike

Now is, what I thought to be, the hardest part. You need unbolt the support for the exhaust pipe. (blue circle on the right)



Next you need to literally pry down the pipe that is on the bike down from its original position about an inch or so. The goal here is to set the hanger that is on the manifold on the bottom of the hanger that is on the bike; wedging it if you will....





Now there's a few ways of performing the next task...



***It's important to understand that the whole manifold is still very secure even with the removal of this hanger***



You can fabricate something to secure the pipe from moving back to its original position, like this. This is really the better thing to do.





Or what I did is I used the original bolt I took off that supported the pipe and put a huge washer on it and fastened the bolt right back on, with the pipe under it. The purpose being that it will not bump over and slide into the original position (if it did slip over, it would cause the new pipe to hit the swing arm). This worked just fine for me!



4) Fitting the new, prepped, muffler on the bike

The outer diameter of the muffler is 2 inches. The inner diameter of the stock exhaust is 2. It does fit. What some people will do is apply a relief cut at the end of the pipe (the pipe that is on the bike itself) for extra clamping power. However, the clamp I used (pictured below) allows for more than enough clamping power.





Now bolt everything back up!



F.A.Q.


Q- Is there a lack of support for the mufflers weight? (If you went the washer route)

A- No, it would probably take at least 50 pounds to move the thing.

Q- Does it rub on the swing arm?

A- I had about a half inch clearance, with full travel of swing arm.

Q- Does your foot hit the can?

A- I wear size 11, and the back of my shoe made contact maybe twice while the time I owned the bike.

Q- Will the heat from the new muffler damage my plastic (because it is closer)?

A- No. There is a black metal shield at the base of the new muffler. This piece will be the only part that will make contact with your plastic. It acts like a heat shield, it will not get hot enough to cause damage.

Sound clip



A better sound clip courtesy of endosj3


Last edited by zac5876; 05-28-2009 at 12:16 AM.
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post #2 of 578 (permalink) Old 08-10-2008, 03:30 PM
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Re: How to convert 03-05 to 06+ R6r exhaust

Nice!!!
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post #3 of 578 (permalink) Old 08-10-2008, 08:23 PM
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Re: How to convert 03-05 to 06+ R6r exhaust

nice write up.. im bout to do this to my 05. could u take a picture of the clamp u used? and what is the HUGE washer exactly doing?


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post #4 of 578 (permalink) Old 08-14-2008, 10:47 AM
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Re: How to convert 03-05 to 06+ R6r exhaust

I posted my experience over on the Exhaust forums.
Stock 08 R6 Can on 08 R6S Complete!!



It was easy. The lower pipe bracket needed to be moved because without it, the exhaust would go right into the swingarm and peg.
And i used the same clamp that held the old pipe on.

Just for updates!! Your mid pipe, i would cut a small slit on one side to allow more clamping power to hold it on.

Last edited by kleners; 08-26-2008 at 08:45 PM.
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post #5 of 578 (permalink) Old 08-22-2008, 04:16 PM
Just made this great wheelie.. did you see it?!
 
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Re: How to convert 03-05 to 06+ R6r exhaust

THANK YOU!!! I wanted to do this really badly! How does it sound? I want something a bit louder than the stock exhaust. How much would someone sell one for?
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post #6 of 578 (permalink) Old 08-22-2008, 04:33 PM Thread Starter
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Re: How to convert 03-05 to 06+ R6r exhaust

...

Last edited by zac5876; 05-27-2009 at 11:45 PM. Reason: Added in original post
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post #7 of 578 (permalink) Old 08-26-2008, 06:18 AM
Just made this great wheelie.. did you see it?!
 
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Re: How to convert 03-05 to 06+ R6r exhaust

Alright, I've got an 08 exhaust coming on thursday and I'll put it on this weekend. I'll post some pics when its done. I'm so pumped!
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post #8 of 578 (permalink) Old 08-30-2008, 12:40 PM
Just made this great wheelie.. did you see it?!
 
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Re: How to convert 03-05 to 06+ R6r exhaust

I got the exhaust and put it on. Here's the pics. It sounds raspy and pretty loud and it looks great. Thanks for the write-up!
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post #9 of 578 (permalink) Old 08-31-2008, 11:19 PM Thread Starter
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Re: How to convert 03-05 to 06+ R6r exhaust

That's awesome! Looks great
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post #10 of 578 (permalink) Old 09-10-2008, 09:24 PM
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Re: How to convert 03-05 to 06+ R6r exhaust

would it be the same if you were to put a two brothers exhaust on it?
looks awesome though.
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