Remus Roxx Install on my 2011 Adventure

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Hondo, Aug 21, 2012.

  1. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
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    Front Range, CO
    I decided to install a Remus Roxx 2 into 1 Titanium exhaust system on my 2011 Adventure Dakar so that I can install a CJ Designs storage box on the other side of the bike and reduce the overall weight of the exhaust system.

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    I bought the Remus Roxx from KTM Twins -

    http://www.ktmtwins.com/ktm-950-990...s-roxx-ktm-950-990-adventure-2-into-1-exhaust

    And the Storage box from CJ Designs/Dual Sport Warehouse -

    http://www.dualsportwarehouse.com/C...STORAGE-BOX-KTM-950-990-ADVENTURE-CJD-ESB.htm

    So what do we have here?

    [​IMG]
    #1
  2. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
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    Besides the titanium can, the kit includes a VERY nice y-pipe, carbon fiber mount and necessary hardware- the only thing missing was DETAILED instructions for the installation.

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    #2
  3. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
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    First things first- I washed the bike off & started to remove parts to get to the exhaust-

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    A last look at the soon to be removed stock cans. The KTM racks, tail rack & side panels all have to come off -

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    #3
  4. Hondo

    Hondo What if it's a Samsquamch?

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    Here I have removed the racks and side panels -

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    The left side panel has the lock cable and the seat release cables attached so I carefully laid it on the tanks-

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    The seat release had to be removed -

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    #4
  5. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
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    After all of that is out of the way you need to remove the cans and then these mounts (both sides) -

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    Then the two exhaust clamps need to be loosened -

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    To get to the clamps easier, remove this nutplate in order to free up the plate that is blocking the clamps -

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    #5
  6. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
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    The pipe then should be loose enough to be easily removed.

    Once the stock y-pipe is removed, you will need to remove the 2 graphite seals that are on the remaining header pipes (if they are on the header pipes). They are unnecessary due to the close fit of the new Y-pipe from Remus. If the seals are inside the old H-pipe that it's you're lucky day - :D

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    I removed them with a pair of needle nose pliers.

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    Also, remove both of the clamps as they will not be needed and won't clamp down tight enough even if you wanted to use them.
    #6
  7. Hondo

    Hondo What if it's a Samsquamch?

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    Then slide the new Y-pipe onto the header pipes. The fit is very good so no seals or clamps are needed. It attached to the reinstalled forward mount -

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    I then placed the carbon fiber mount band on the can and slipped the can onto the Y-pipe and attached the included springs -

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    here the can is fully installed -

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    #7
  8. Hondo

    Hondo What if it's a Samsquamch?

    Joined:
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    Here's the ADV all buttoned up with the CJ Designs Storage box installed on the other side -

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    I'm off on a ride to see how it feels with the new exhaust - :pynd
    #8
  9. Hondo

    Hondo What if it's a Samsquamch?

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    Finished - :D
    #9
  10. mousitsas

    mousitsas Long timer

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    Reserved!






















    Opinion that is, until I see some dyno!
    #10
  11. jnberr0

    jnberr0 6Ninety Pilot

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    Nice stuff, Hondo.
    #11
  12. Thumdar

    Thumdar Adventurer

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    Another classic Hondo how-to thread. :deal

    Let us know what kind of performance change there is.
    #12
  13. Hondo

    Hondo What if it's a Samsquamch?

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    I just did a 50 mile loop around town and on the freeway -

    - can't really feel much difference, maybe more low-end torque
    - sounds wonderful
    #13
  14. GZERO

    GZERO Fixing stuff around

    Joined:
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    great write up, altough it took you a while to write it :freaky
    How do you feel the top end?
    I always told people that the regular 2 to 1 welding the stock h pipe killed the top end because of the collector itself, but the remus roxx supplies his own collector and i bet that doesn't kills the top end but it does gives you bottom end.
    The roxx is in my list of things to do.
    Is the sound loud? if is louder than stock, but a little more quiet than the akras with the baffles then i can live with that. (i'm turning 30 soo i guess i'm kinda old already :cry)
    What about the temps? is it cooler?

    thanks for the write up.
    #14
  15. Hondo

    Hondo What if it's a Samsquamch?

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    Overall rideability & throttle response seems about the same, maybe peppier on the low end.

    The sound is great with the insert installed- haven't tried it with it removed.

    Getting old at 30? :rofl

    This 50 year old loves the sound and get's a great, big hooligan smile when I roll on the throttle- it's great IMO!
    #15
  16. GZERO

    GZERO Fixing stuff around

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    lol, i know that, but the thing is as an enduro rider i've come to hate loud exhaust, because it's useless.
    i also burned that phase (loud cars, loud bikes) so i have come to terms in this.
    Come one! tell you you can stand the 2 akras without the baffle on a 5 day trip? if you say yes you have to be lying.

    :freaky
    #16
  17. Hondo

    Hondo What if it's a Samsquamch?

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    On the freeway it's not much (if any) louder than the stock cans.

    It seems to "BRAP" louder when you rev it - it's a straight through design so I expected that.
    #17
  18. SierraJeep

    SierraJeep It's toast

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    Why did you bother to remove the graphite seals from the old H pipe if they were not needed with the new Y pipe? (I left mine in the old pipe just in case I had to reinstall it for some reason, such as an inspection if I got into any legal trouble.) Also, I didn't have to remove the seat release either, I am curious why you had to do that?

    Nice looking bike. How many miles are on it?
    #18
  19. Hondo

    Hondo What if it's a Samsquamch?

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    The graphite seals were in the way ie the header's outside diameter was too big with the seals in place.

    The Remus pipe was a tight fit on the bare header pipes.

    As far as the seat lock goes, I wanted to lay the left side panel up & away from the middle of the bike and as the seat lock & cable are attached to the side panel, I had to remove it.

    Only 3000 miles on the ADV...........
    #19
  20. SierraJeep

    SierraJeep It's toast

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    Oh, okay, that makes sense. Mine were stuck on the inside of the H-pine so they came off with the H-pipe. Yours must have stuck to the header instead.
    #20