Exhaust System Replacement

[Prof J]

My 2 cents: I did not install block off plates. Disabling in the ECU seems to work fine. You can get the butterfly actuator out fine with the battery in the bike. Nice write up.

PhukDD, you have a Vcycle flash from David, correct? I thought I read somewhere that having the Vcycle flash meant that the 'pair' setup 'should' be blocked/plugged/disabled was sort of a 'need', or maybe a 'have to'/highly recommended for the bike to perform best with his flash?

I do not, but all flashes that disable, do it the same way. I did not install the block offs and my bike does not back fire. My understanding is that the ECU holds the pair valve closed, so no need to further block it off.

PhukDD, good demonstration of software over hardware.

I blocked them on my 14, and I'm given to repetition if it works.

Nice to know that it is not 'necessary'.

Thanks.

[Champ87]

If anyone wants detailed step-by-step information, let me know and I’ll cook up a Champ87 guide with lots of photos.

Here's a guide to help those who are thinking of replacing their exhaust system and want to know what's involved.

Kawasaki_H2SXSE - Exhaust Replacement.pdf

(7.48 MiB) Downloaded 300 times

[Jayster4867]

This a great guide thank you .

I was considering trying to buy all the parts as im in the uk so shipping for this package is probably ridiculous. However , these notes make me realise all this is beyond my capabilities . Still havent found videos or pictures for this mod and knowing my limits will save my bike

[Champ87]

Still havent found videos or pictures for this mod and knowing my limits will save my bike

I haven't done a video but the pdf guide posted above contains plenty of pictures and step-by-step guidance. I would say the most effort goes into removing the secondary air system. That's optional - you could simply have your tuner disable it in the ECU when the fueling is remapped to suit the exhaust.

Changing the exhaust system is not a big job. It should be well within the capabilities of anyone who is used to doing their own maintenance. If you aren't comfortable doing the work described in my guide then you made the right decision. Knowing your limitations is smart thinking.

[dieseldad60]

If anyone wants detailed step-by-step information, let me know and I’ll cook up a Champ87 guide with lots of photos.

Here's a guide to help those who are thinking of replacing their exhaust system and want to know what's involved.

Dang Champ!! That is an awesome guide!! Really incredible and professional level work there! Thanks for all you do for the H2 community!

[Champ87]

Dang Champ!! That is an awesome guide!! Really incredible and professional level work there! Thanks for all you do for the H2 community!

The appreciation is welcome but one handclap would have been enough! Truth is, only a small part of this guide was done with the H2 community in mind. Since many of the tasks that I do on this bike are first time, I refer to the factory service manual a lot. Jumping around from one section of the manual to another to find the necessary information interferes with my work flow so I pull the relevant parts into a single document and get myself familiar with the tasks before I even step into my workshop. I’m also in the habit of taking plenty of photos in case I need to look at those on reassembly or for future reference. Up to this point all the work is for my own benefit. It’s not such a big step to pull all that together in a format that I hope will help others.

To give some background to why I enjoy doing this – it started about 10 years ago when I owned a Triumph Sprint. I was surprised by how many people were intimidated by the thought of doing a valve check/adjust so I put together a thread on the Triumph Sprint forum explaining the steps. Originally, it was intended for those who might be tackling valve adjustment for the first time, but I soon discovered that it helped experienced wrench-twiddlers who wanted an overview of the process. Also, those who would never consider doing the work themselves got a better understanding of what the dealer was charging them for and why there was a wide variation in prices quoted by dealers (cost of valve check vs. valve adjust). That thread has now had over 82 thousand views. If only 1% of those found it useful that’s helping a lot of other bikers. That gives me a good feeling. Nobody loses. I’m glad to see it continuing through this forum.

[Jayster4867]

Still havent found videos or pictures for this mod and knowing my limits will save my bike

I haven't done a video but the pdf guide posted above contains plenty of pictures and step-by-step guidance. I would say the most effort goes into removing the secondary air system. That's optional - you could simply have your tuner disable it in the ECU when the fueling is remapped to suit the exhaust.

Changing the exhaust system is not a big job. It should be well within the capabilities of anyone who is used to doing their own maintenance. If you aren't comfortable doing the work described in my guide then you made the right decision. Knowing your limitations is smart thinking.

Thanks you very much for the pdf . Its great that you took time out to help guys like myself .

[JoeBurns]

Champ87 you are my new hero! For the next week or two for sure! I am starting the block off plates and I don’t see the EVAC Canister. I can see the air switch valve and just about anything else down there but no EVAC. It should be on top pretty much? My bike is a 2018 purchased in the USA. I will try to attach a pic if I can. Thanks! Joe

[Snakes709]

Champ87 you are my new hero! For the next week or two for sure! I am starting the block off plates and I don’t see the EVAC Canister. I can see the air switch valve and just about anything else down there but no EVAC. It should be on top pretty much? My bike is a 2018 purchased in the USA. I will try to attach a pic if I can. Thanks! Joe

north american bikes (aside from commifornia) dont have the evac canister.

[Champ87]

..... I don’t see the EVAC Canister. I can see the air switch valve and just about anything else down there but no EVAC.

As snakes709 said, the EVAP canister is a California thing. However, the way the bikes are allocated to dealers means that many bikes with EVAP will go to other states. Mine is an example of that - I bought the bike new from a local dealer and I live nowhere near California. Lucky for you, your bike doesn't have it so that's one less thing to bother with.

Hope my little guide helps.