adapt the GSXR600, GSXR750 or GSXR1000 pipe to the DR650

Discussion in 'Thumpers' started by B1, Jun 13, 2011.

  1. B1

    B1 Carbon-based bipedal

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    This GSXR mod works incredibly with the 'BST magic' mods - cheap do-it-yourself mods to the stock DR650. Read about it all in this BST magic thread. This info applies to 1996+ models only.

    WHY ADAPT THE GXR600 GSXR750 GSXR1000 PIPES TO A DR650SE (1996 to current models)?
    It's around half the weight of the stock pipe, and about the same as most aftermarket pipes.
    Dyno charts show it gives around the same performance increase as aftermarket pipes.
    It's far quieter than aftermarket pipes, but has a nice note and louder than stock so you can actually tell which gear you are in at speed.
    It's good for the environment - you are recycling a can that would otherwise just sit in a wrecker's shed instead of buying a new one with all that expensive carbon-intensive alloy.
    It doesn't need repacking.
    Extra performance and no loss in fuel economy (if you keep the airbox and jetting as standard).
    It looks legal - if aftermarket pipes can get you booked in your country, then this comes stamped Suzuki and your average cop wouldn't have a clue it's not the stock pipe. And it's still very quiet so they shouldn't bother anyway.

    the GSXR exhaust works brilliantly with the carbie mods in this video.




    IS IT CHEAPER THAN JUST BUYING A POWER PIPE?
    It can be an incredibly cheap mod if you get the pipe cheaply from the wreckers, and make your own mid pipe, quite a few guys have done it for around $50 or less. It will still be pretty cheap if you buy an aftermarket mid-pipe and get the can cheaply (say under $50). But if you pay a fair bit for the can it will probably come out to the same as buying a new power pipe, although you still have the advantage of a quieter bike and it looks completely legal with the Suzuki markings etc.


    HOW MUCH EXTRA POWER WILL I GET? AND WHAT DOES IT SOUND LIKE?
    Here's a dyno chart that shows the GSXR1000 pipe matching or slightly outperforming the FMF pipe over most of the rev range. Please note I don't know what jetting was involved, the results came from this site here.

    [​IMG]

    This Youtube clip let's you see and hear the difference between a GSXR pipe and the stock can.

    <iframe src="" allowfullscreen="" frameborder="0" height="375" width="640"></iframe>



    WHY IS A MID PIPE REQUIRED? HOW DO I GET MY HANDS ON ONE?
    You can use your existing header pipe, but will need a midpipe with a flange to connect to the four bolts on the GSXR muffler. You can buy an aftermarket one ($200 to $300) or make your own if you can access some pipe bending and welding equipment. Alternatively, try an exhaust specialist - I went this option and this Brisbane, QLD, Australia mob only charged $180 to make all the fittings and install as well. Bargain!

    The Hindle P/N DR650S0SS slip-on stainless steel mid-pipe pictured below. Uses the stock DR head pipe joint gasket. Some guys report problems with the HIndle pipe making contact when the suspension bottoms out and eventually cracking? Check out this post but make sure you read all the responses including the manufacturer's response before making a judgment on whether it is the user's fault or Hindle's fault....

    [​IMG]

    Another option is the Two Brothers mid-pipe pictured below (on top of the Hindle unit). It too is stainless steel, provides more rear brake line clearance than the Hindle pipe, and puts the GSXR muffler at a steeper angle.

    [​IMG]

    Jesse at Kientech does mid-pipes as well, including a wider diameter one for the oversize FMF header pipe.

    [​IMG]

    These mid-pipes will come with a bracket for bolting your GSXR can to the frame. If you make your own mid-pipe you'll just need to make your own bracket like the one below. It's very handy that the GSXR cans line up as well as they do.

    [​IMG]



    WHICH GSXR PIPES WILL WORK ON THE DR650?
    You've got a fair bit of choice here, depending on how fussy you are about size, weight and performance.
    The lightest can is from the GSXR1000 2001 and 2002 models. This one is shorter and lighter due to a fair bit of titanium. Make sure it is stamped x40F0x.
    Second best option is the GSXR1000 can from the 2003 and 2004 models. It will be stamped x18G1x. Slightly heavier, longer and fatter but still fits very well.
    Third best option? GXR600 2001 to 2003 models and GSXR750 2000 to 2003 models. This version has steel internals so a bit of extra weight (but still far lighter than the stock can!) and a smaller outlet pipe so it's quieter and a bit more restrictive. It is stamped "35F01" Suzuki P/N 14310-35F01-H01.

    Other options include getting aftermarket GSXR pipes, although the problem here is they are often very loud with no power advantage, and while there are some very cheap ones on Ebay they are usually very poor quality.

    The pic below shows an R1 muffler, then the GSXR1000 (02 & 03) then the GSXR1000 (01 & 02) from top to bottom. Technically you can make most cans work, and some guys have adapted the R1 can to the DR650. It's a big mother though, the big advantage of the GSXR pipes is they are very small, light, and require the least work to fit to the DR650.

    [​IMG]

    Obviously everyone tries to get the GSXR1000 2000 or 2001 model but it does make these scarce and/or expensive. If you have concerns about the larger size of the 2003 and 2004 models here is a pic of it fitted to my DR650. Tucks away very nicely, but I think this is because the exhaust specialist put a lot of effort into making sure it didn't poke out the back too much.

    [​IMG]

    Below is the smaller GSXR1000 (2001 or 2002) can with the Hindle mid-pipe.

    [​IMG]



    WHAT ABOUT A SPARK ARRESTER?
    Please note, the GSXR pipe doesn't have a spark arrestor. In some countries this can be a big issue. FMF have a screen type SA that pops right into the back of the GSXR muffler. See this link for more info and pics.

    WHAT ABOUT JETTING?
    The stock muffler is so restrictive that you will notice better performance immediately with the GSXR pipe. However, to maximize the benefit you should rejet and open up the airbox too. We cover cheap do-it-yourself mods in this BST magic thread, otherwise just buy an aftermarket jetting kit and open up the airbox.

    CHECK THAT HEADER WELD
    At the header flange, where the exhaust pipe meets the cylinder head, there is often a big glob of weld. If your DR650 has this, then you can file it back to improve exhaust flow. Might have just been on older models, but worth checking while you've got your mid-pipe off.

    This has been collated from various sources, but particular thanks to the guy who did this webpage (check it out, heaps of info and pic there) and guys from the Thumper Talk and DR Riders forums as well, a lot of their info is in here.
    #1
  2. SamM

    SamM Jeep Overlander

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    Very good information johnnok! I'd like to also add that the 2000 and 2001 Suzuki GSXR100 X40FOX Titanium muffler can also be fitted to the KLR650. My muffler was purchased off eBay for $25 and it included the stock GSXR1000 midpipe. I was able to sell the GSXR midpipe for $25 which netted me a free 3.8lb titanium muffler. Still can't believe that deal. I purchased a DR650 flange ($15) from KienTech and a KLR650 stainless steel midpipe ($99.95) from Hindle. What a difference! I highly recommend this muffler. It never needs packing and has a great sound. Worth the effort!

    My muffler sits a little further back on my 2008 KLR than I'd like. There is plenty of room for it and I plan to fix that!

    SamM

    [​IMG]
    #2
  3. gplassm

    gplassm Been here awhile

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    While some money can be saved going the GSXR can route, the biggest problem is that the mid-pipe is not easily home fabricated. By the time you buy the mid pipe kit, and the can, you can end up very close to the price of a bolt on solution. Somebody here used a Yamaha WR450F can and it worked well, but I do not recall how he solved the mid-pipe issue...
    #3
  4. rowie

    rowie Been here awhile

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    For the people with the RS model (1990 - 1994. Not sold in the USA) the GSXR muffler is too big and won't fit without major surgery to create enough clearance with the tyre and sideplate.

    In this location, a 5.30 tyre will hit and it needs to be moved out at least 3/4"

    [​IMG]

    [​IMG]

    The only option for a slip on that I could find is a Marving, which are made in Italy. They are chrome steel and it weighs about 2 pounds heavier than the GSXR, but is still much lighter than the boat anchor twin system that was installed on the RS :D

    [​IMG]

    Comparison shot:

    [​IMG]

    They also make mufflers to suit newer model DR's, so they are another option.

    Cheers,
    David.
    #4
  5. B1

    B1 Carbon-based bipedal

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    agreed. in my case the exhaust specialist did all the fitting and parts for only $190, and i only paid $50 for a scratched GSXR can which came up nicely with some sanding and polishing.

    i still think some guys might shell out the big bucks though, if they want the same performance increase as an aftermarket pipe but keeping it far quieter and looking stock...
    #5
  6. doug s.

    doug s. Long timer

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    also note that the first post in the above-referenced thread was someone using the HINDLE muffler, not the gsxr mufler, so mfr's response saying it's cuz a gsxr muffler was being used was a bit off the mark... personally, i would go w/one of the other alternative midpipes.

    i went w/the high-flow kientech to use w/a high-flow fmf powerbomb header, and it worked fine. i did have to trim the rubber grommet i the frame where the unit attaches, tho, to pull the pipe away from the shock a bit, and closer to the frame, so it wouldn't rub the shock spring:
    http://www.advrider.com/forums/showthread.php?p=16965800&highlight=doug#post16965800

    regarding other aftermarket choices besides the gsxr can, i sourced a tsukigi can for the '01-'04 gsxr, and it's excellent - open design, not too loud, and does not need repacking. (pics also shown in the post i linked above.)

    doug s.
    #6
  7. eakins

    eakins Butler Maps

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    at this point I'd would not consider Hindle an option for anyone as that pipe has a very deep bend (too deep and it hits?). i'd go w/ the keintech option as that is a a known good pipe.
    #7
  8. Fishnbiker

    Fishnbiker Tire smuddy, hook swet

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    I'm now looking at taking the 40FO off my Tiger to install on my new '08 DR. Anyone know for sure what metals the GSXR headers & mid-pipe are made of? Is the titanium content restricted to the muffler, with stainless headers, or is the whole system unobtainium? The metal is burnt blue to near the tail where it yellows. Very thin walls, very light.

    I have enough of the GSXR header & mid-pipe to redo a match up, but only if It's not too expensive to weld.

    The 40FO has been on the Tiger for several years with no issues other than a few dents.

    Thanks,
    #8
  9. kezzajohnson

    kezzajohnson kezza

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    Great Mod. Great thread.

    I managed to get a X40FIX titanium and here's what I did.

    The mid-pipe issue can be a bit of a drama. I happened upon a local engineering shop that had been making some practice handrails from stainless steel which had 90 degree mandrel bends and I scored a couple of offcuts and took them home to play with some angles etc. After I had worked out the angles and length, I cut them as marked and took them back in to the engineering shop to have them joined (stainless steel weld). I couldn't be bothered trying to sell the stock muffler and wouldn't be needing it anymore, so I cut the front section off that (also Stainless Steel) which contained the mid mount in order to have that joined on to the midpipe.

    A fellow ADVer in Brissy, helped me obtain a laser cut stainless steel flange.

    I made a rear mounting plate myself and used a rubber grommet from the stock muffler to mount between the GSXR muffler mount and the mounting plate.

    After the midpipe was fabbed, I fitted it all up to the bike including the flange bolted to the muffler but not yet welded to the midpipe. I then took the whole bike in and had the flange welded to the midpipe with everything in place and at the right angle.

    I can't say it was necessarily a cheaper option by the time I paid the engineering shop for bits and pieces and welding and then the flange, but it was a challenging project all the same.

    No fitment issues and never any issues with rubbing anywhere or hitting anything, no cracks or breaks after about 4 years.

    Below: initial cut and angles with portion from stock muffler for mid mount

    [​IMG]

    Below: Home made rear mounting bracket

    [​IMG]

    Below: Drawing of dimensions for flange: Note: ID will vary depending on midpipe used.

    [​IMG]

    Below: Finished product (foot not included)

    [​IMG]

    [​IMG]
    #9
  10. dogjaw

    dogjaw plays well alone

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    Another option is the 24f0 off of the Hayabusa; very plentiful as there were many more years involved, and each bike has two. The DR seems to like it better than the other options, as it seems to have the perfect amount of restriction, especially with stock or minor mods to the jetting.The 40f0 weighs 4.5#, the 35f0 and 24f0 both weigh right around 7#; pretty substantial savings over the 18# stocker. I found the Holy Grail of exhausts some time ago, a whole pile of pristine Suzuki takeoffs; bought every one for 20.00 each, 3 40, 7 35, and 21 24's; I felt like King Midas.

    Jesse at Kientech has recently fitted an 18g1, and says it works great; haven't tried it on mine, but if Jesse says it, you can take it to the bank. I've got some video comparing my son's 24 to my 40, I'll see if I can't dig it up.


    The Ride for Trevor:
    http://advrider.com/forums/showthread.php?t=941454
    #10
  11. dogjaw

    dogjaw plays well alone

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  12. B1

    B1 Carbon-based bipedal

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    nice! seems crazy suzuki doesn't put these on from scratch. surely they can't cast much more than the huge convoluted stocker...:huh
    #12
  13. dentedvw

    dentedvw Where did I put that

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    Is it possible that there is an aluminum flange on my bike?
    Previous owner put the kit together himself, apparently with Kientech parts. The flange that you bolt to the exhaust can is not welded to the pipe, so the connection between the pipe and the can rattles and exhaust escapes that side.
    I was comparing it to another rider's bike, and his is welded. Mine is not. I scratched the flange on mine, and it gouged like it is made of aluminum.

    I was hoping to have it welded on, but I can't tell if it's stainless or not. If I removed the whole thing, I guess it would become obvious quickly though.
    #13
  14. rosiethestarfish

    rosiethestarfish Adventurer

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    Found a x40F1x (aussie equivalent to x40F0x) but the wrecker wants $200! $200 for a stock tube, I was pretty upset but unfortunately wreckers don't usually haggle. By the time I buy the mid pipe from Kinetech and get it shipped to Australia the whole system would cost me $550. I think I would be better off with a Barrett slip on...or I will just keep looking
    #14
  15. bankerman

    bankerman n00b

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    Hi Guys,

    Will an 09 gsxr 600/750 can work also?
    #15
  16. SDIZZY

    SDIZZY Been here awhile

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    Right now I have a 2Brothers Racing M7 mounted up to FMF powerbomb.

    I scored a x40F0x and am wondering if the midpipe can be reused from the M7, or I will need to order the oversize one from JNS?
    #16
  17. MrBright$park

    MrBright$park Adventurer

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    Can anyone measure the length and the diameter of these cans? x40F0x, x18G1x, 35F01? I think of fitting one to my Aprilia Pegaso and would like to see how it will look like.
    #17
  18. Old Kiwi#99

    Old Kiwi#99 Been here awhile

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    x18G1x is 21' long x 5" diameter. The one on my KLR is shortened to 16" long - stuck out too far.
    #18
    MrBright$park likes this.
  19. MrBright$park

    MrBright$park Adventurer

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    Thank you very much, Old Kiwi#99! Is 21" is the full length or cylindrical part only?
    #19
  20. Old Kiwi#99

    Old Kiwi#99 Been here awhile

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    The was just for the can, not counting the mounting boss or the tailpipe extension.
    #20