Ok, so here's the mother of all how-to's - "installing a stubby exhaust for your 03-05 R6 or 06-07 R6S." Yes it works, no it's not a lot of work and yes its freaking awesome. Bigger pictures are available, just PM me.
Pictures will be at the end of the threads - 2 successful pipes done.
1/4" Black Steel (or whatever you want)
#6 metric hex allen wrench
12mm socket wrench
Pliers or Vice Grips
A vice (it helps A LOT)
Drill with a 1/4" bit
Some bolts with lock nuts. 12mm's are a good size.
I think that's it
Let's get down and dirty!
I assume you have already removed the stock exhaust. I'll write a howto later on to do that. For now, search the boards I'm lazy.
You need to drop the midpipe down about 1” in order to fit the snug the new stubby on without rubbing the swingarm. What I did here was took the black steel and created a bracket. This bracket is about 1.5” with 1” between the centers of the holes. You may need an assistant here to help wedge the midpipe down a bit.
Place the crowbar over the midpipe and push down. Install the bracket while the midpipe is lowered. You will have to hold this position until the bolts are tightened. I'm not going to explain much here, I hope you have an understanding.
Here’s the bracket
Before bracket is installed
After bracket is installed. Notice you will need a nut and bolt here. Make sure they're snug and make sure your using a lock nut.
Notice the drop – good. Put the new pipe in to verify it'll fit without rubbing. If all is well. Good. If not, you might need to make another backet to drop it down further.
Now, that hard part. Time to fabricate the bracket to hold the exhaust in place. I chose to install this bracket to the back of the peg. So this requires removing the rearset and removing the peg. Now this might be a PITA because of the lock-tight but you'll get through it. Pour warm water over it if it's tight. It'll help loosen the lock-tight.
Rearset is held on by 2 screws. Once they are out it'll give you enough flex room to move the rearset around so you can view the back.
Looking at the back you'll notice the screw holding the peg on. This will need to be removed. Hold the peg with a set of pliers and unscrew the hex screw. This part is PITA part I mentioned above.
Great, now your almost there. Time for the most time consuming part. This is where your going to make the bracket to hold the exhaust to the peg. Measure twice cut once. Keep that in mind. Also take note that you may have to install the rearset a couple of times to make sure the bracket is fitted correctly.
Line up the steel, make sure it aligns properly. Notice I had to make some cuts to make it fit snug where it wouldn't wobble around. Things are flush this way. I took an estimate of how many inches I'd need to get the steel from the back of the peg to the bracket of the new exhaust. Roughly 7-8" for starters, then cut as necessary. Mark the hole and drill.
Voila, one side done. Time to bend the bracket to fit around the swingarm and angle the exhaust out a little bit. This step required the vice for me. Since I had no protractor, I bent a little then fitted it to the exhaust and the rearset to assure it'll work.
Install the bracket and put the exhaust in place. This is where you'll fit the bracket for the second hole mounting the bracket to the exhaust. I forgot to take pictures so I'll piggy back this one.
Drill the holes and make the appropriate cuts to size down the bracket to look elegant. The hole for the exhaust clamp had to be drilled at an angle so the bolt would go through and sit flush on the clamp.
Finished bracket woot
Install the bracket to the rearset then reinstall the rearset. Tighten it all down. Install the exhaust and make sure all fitmet is correct.
OMG ALMOST DONE! This part is [INCOMPLETE]
Notice the exhaust just sits inside of the midpipe. We will have to enlarge the exhaust pipe to fit very SNUG inside the midpipe. For this we will have to get a pipe expander. You can rent these for 20$ at autozone. Once you return it you'll get your money back. Good deal eh. I will provide pictures tomorrow when I get the dang pipe expander. I'll write the instructions for it now though.
Put the pipe expander inside the exhaust pipe and enlarge it by 1/16" - 3/32". It's not a very big change so do it slowly and check it often. Once it fits snug, voila your done.
Dont forget to install the exhaust clamp.
If your still having leaks, pick up some exhaust putty. Apply this to your putty to your exhaust pipe smoothly. Once it dries, it'll expand and harden. To break this seal, just bang the mid-pipe once of twice and it'll fracture off.
Questions or comments?