Aus-Air - Cold Air Induction Kits

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Aus-Air Cold Air Induction Kit

Stage Three - The Exhaust System

The final stage in modifying your bike is to fit a free flowing exhaust system that compliments the air induction and fuel management systems.

This can be achieved by two separate methods. We spoke earlier, about modifying the original Kawasaki exhaust system to relieve the exhaust gasses, and still retain the original exhaust appearance whilst keeping to the original principle of a cost effective modification.

This is achieved by removing the exhaust system from the bike and cutting the rear ends out of the stock mufflers. Then welding new ends onto the mufflers that include slip on pipes.

Two new engine pipes are fabricated and bent so that the original heat shields will fit to the new pipes. A balance pipe should be fitted between the front and rear engine pipe. This is usually located just before the mufflers and it should be a slip fit connection so the new system will fit correctly. The heat shields will dictate the final length of the new pipes.

The muffler baffles can be addressed when the rear of the mufflers are removed, however, we have found that modifying the baffles does not lead to better performance. Rather, this procedure mainly increases exhaust noise.

It is also of note, that the vibration in the right hand passenger foot peg may increase. This is mainly due to the fact that the upper muffler is not equally balanced from the original rear exhaust mount. This procedure will leave you with an exhaust system that does the job, looks original and doesn't cost the earth, but it does have limitations.

If you want to go this way, find a good exhaust shop and discuss the procedure before starting the modification. Make sure the shop understands what you want you want to achieve. Don't forget that you MUST block off the air injection ports to each cylinders reed valve.

Click here to view a printable version of this principle that you may take to your local exhaust shop.

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Second Method

We have always adhered to the principle of developing a good and cost effective exhaust system. To this point, we have never been able to justify the fitting of costly imported exhaust systems.

Further to this, we have been working with an Australian exhaust system manufacturer and they have delivered an exhaust system that compliments our air induction kits. This exhaust system is better than the equivalent imported systems that are currently available.

Not only does it look good, but it allows for the fitment of the original heat shields. So, at first glance, this appears to be a standard exhaust system until one takes a closer look. The pipes are tucked in close to the engine cases, and there would be little chance of the exhaust dragging on the roadway during hard and fast cornering.

The lower exhaust pipe, while tucked in tight, still allows for the engine oil sight glass to be read with less difficulty than the original factory system.

Not only does it look good, but it sounds great too (A bit like an old shovel head harley in my humble opinion: Andy). Not too loud, but still lets you know that you have something better than a choked up standard system attached to your bike.

The exhaust noise level at idle is just deep and throaty enough, and at highway speeds, again sufficient that the bike sounds nothing like the original system. In other words, throaty and with a good rumble without being intrusive.

Performance wise, we have tried several imported exhaust systems, and have found that this system equals or exceeds the overall performance of the imported systems we have tried. Torque increased well above what is delivered by the modified original exhaust system.

To suit individual tastes, the pipes are available in both slash and straight cut styles. Because the mufflers are balanced on the rear exhaust mount, vibration in the right hand passenger footrest is at a minimum, much less than the original factory system.

As the exhaust system has been designed and tuned, it does not require a balance pipe between the front and rear exhaust pipes. The muffler inserts are removable at any time.

Designed for those that want the ultimate performance exhaust system.

A really great exhaust system that we recommend to compliment our induction kits.

It is recommended that the hoses to each air injection reed valve be blanked off to complete the installation of any modified exhaust system.

Further information is available direct from the system manufacturer, Formula 1 Exhaust Systems. Phone (02) 6765-8646.

Click here to go to the Formula 1 Website.

Like All Our Induction Kit Components
This System Is Australian Designed And Manufactured.