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How to convert 03-05 to 06+ R6r exhaust

181K views 581 replies 174 participants last post by  bartol435 
#1 · (Edited)
**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 :dunce:



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

[URL=http://s263.photobucket.com/albums/ii156/jabdelja/?action=view&current=CIMG0211.flv][/URL]
 
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#515 ·
question.. obv you CANNOT cut a releif cut in the muffler.. its titanium.. it doesnt bend.. are u all putting the titanium over the mid pipe or are you putting the midpipe inside the muffler pipe??
 
#518 ·
Hey guys im planning on doing this soon. Question. Does the black shield need to be trimmed at all? Or will it clear all the internal parts ok. Does bending the exhaust down touch the bottom of the fairings at all? Also. how deep do recommend the slits on the pipe (one connected to bike) to be? :nocontrol
 
#521 ·
Does anyone have the dimensions of the two brackets used to lower and secure the exhaust? If I remember right, I want to say the main lowering bracket was 1 7/8 from center to center, is that about right? What about the bracket you guys have used to secure to the rearset? Any info would be much appreciated!!
 
#525 ·


I just did this the other day and it only took me about 20 min after I cut the end off. I LOVE IT! sounded louder than i expected but i still like it (i just keep out of it in the neighborhoods) as for keeping it on there i used a band clamp and then one of the springs off of my slip on and putting it through one of the bolt holes down to the "bump stop looking thing off the exhaust to the fairings" it holds SUPER well and sounds and looks great!
 
#527 ·
most of the people made the bracket if they used one. just from some aluminum or steel. i personally just used the spring that i showed you in the pic and a clamp and i couldn't pull mine off if i tried. i check it all the time just to see how its holding on. ONly have about 1000 miles on it tho
 
#531 ·
Thanks for the "how to". Works and sounds better than my old one.

Question though, I put the 06+ stock exhaust on my 04 R6 as instructed on (Been on a few months now, no problems) and have a K&N air filter on the bike too. I have a Power Commander III but not really sure what map to put on it. Does anyone know or has anyone made a custom map I can use?
 
#532 ·
I've been checking this thread every couple months hoping someone would put up a custom map, but it's getting on to a year and no luck. I've even offered people cash, but no one ever seems to get around to doing it.

I'm running the LOR map from the Dynojet site. It doesn't backfire as much.
 
#534 ·
had this on for 7 months and it finally fell off on me :( it was hanging while i was on hte freeway i didnt lose it though haha put it back on and it still seems strong id really commend the slits if you can to clamp it on better i feel like my clamp is worthless i even have 2 springs from my old exhuast to hold it on the pipe thats what saved it from getting lost on the freeway was 1 of them stayed on
 
#535 ·
I cut a couple of slits with a hack saw then used a cheap clamp from Autozone. I couldn't get a tight seal without them. You want to make sure the cuts are deep enough to get a clamp around it but not too deep or it will leak. The exhaust is really sturdy without any additional support. I had a 30-40 mph lowside and rashed up the right side of my bike without any issues.
 
#536 ·
im in the process of doing this now, started it with the muffler off sounds like a cammed small block chevy lol, cant wait hopefully goes well
 
#537 ·
got it done

 
#540 ·
Looks good. Have you considered spraying the can black with high temp paint? Would look hot on your bike. Done it to mine but my bike is red.

Secondly I removed that block thing attached to the swingarm because it was literally 2mm from touching the can.
 
#539 ·
and i can also say i LOVE the sound it makes :)
 
#541 ·
Haven't thought about it yet, kinda like the oem look
 
#542 ·
I'd do this mod but I need a lil back pressure for the lot.
 
#544 ·
I just ordered a muffler from an 08 R6 to install on my 09 R6s. I'm hoping to do it within the next few weeks, but I will be getting a PowerCommander in order to get the correct f/a ratios and not screw up my engine/valves. My question is, for those who did some tuning and have the power commander, what unit did you buy, from where, and what map are you using? Thanks!

I haven't the time right now to go through the whole thread so forgive me in advance if I'm asking a question that was already answered.
 
#546 ·
If you're going for straight power, using a shorty slip-on with stock headers is going to cost you a couple hp. You don't really need a PC for what you're doing. The stock ecu will adjust f/a enough that you probably won't notice it. PC is for serious mods (engine mods, full exhaust system, etc).

You need the PC for the R6s. Some of the other years can work but you have to alter the electrical connections to get them to fit.
 
#547 ·
My impressions from doing this yesterday on my R6S:

The new exhaust touches the plastics. I haven't ridden the bike yet so I'm unsure if the exhaust will melt the bottom fairings. I used the washer trick just like the original thread member.

Also, the clamp on the titanium exhaust is very close to the swing arm. In my opinion, it's probably a good idea to cut it off. I understand that many people are using it to fasten the exhaust to the foot peg but it is so close to the swing arm. Most likely it will rub. I think i'm going to cut it off before it rubs on the swing arm.

I did not cut my stock exhaust manifold pipe to get the titanium exhaust to fit. I heated up the pipe and it actually slip all the way in to the bead of the titanium muffler. I put an exhaust clamp on it to secure it. It took me two times to heat the pipe enough for it to slide all the way in. The first time it only slid in half way. It was a PITA to get back off. The second time it went in perfect!

FYI- The titanium pipe was a PITA to cut!
 
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