Brodie's W800

Brodie

Gold Coast, Queensland
Ha!

One day, when this isn't my daily.

There is also a 855cc kit but I don't think going for a resleave is a great idea on a daily.
 

Brodie

Gold Coast, Queensland
30 day post warning. Excellent.

Work has been kicking my ass lately. 5 days off this year so far.

Anyway after having ridden this bike as a daily for a few months now I can note that the stock exhaust is horrible. It is the first thing that needs to go once cash permits. Not much in the way of aftermarket exhausts unless I import one from Europe or Japan. I have had one quote done for a 2-1 which came in at $1000.

So the stock exhaust is a dual wall fulled welded to the muffler system. The only join is the link pipe between the headers but even the T off is welded on. There is a cat in each muffler and from what I can find the stock exhaust weighs somewhere around 14kg. Most after market ones come in at around 7kg.

Here is a photo from late last year on a ride out to Boonah.



Ohh and the US gets the updated version of the W800 this year. Slipper clutch, ABS, rear disk and a bad paint job. Not sure I like it. But there might be a few parts that can cross over we will have to wait and see.
 

Brodie

Gold Coast, Queensland
I picked up a power commander today for once I get a decent exhaust. The bloke I bought it from was kind enough to give me a stock exhaust system as well.

So in the interest of information gathering I decided to weigh it. My scale only reads to 8kg so I had to weigh each side seperatly. This exhaust also has the end baffles removed which would reduce the weight slightly. I left the flanges hooked on to compensate for that.

Kawasaki W800 stock exhaust weight.
15.13kg
 

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Pete12

Member
Hey Brodie, I think Staintune make mufflers for your bike, probably worth a call if you're interested.
 

Brodie

Gold Coast, Queensland
Thanks Pete,

I had a look and they have them listed as sold out. Price was $1900.

A quick quote I had done was for $1000 for a 2-1 mild steel exhaust.
A mate of mine has offered to weld up a system for me if I buy all the pipe work and lay it out how I want it.

I am in no rush though. I want to keep a really high standard for this bike.
 

der_nanno

Faster!
Well, if you were in a country with one less "L", I'd say we could fabricobble a stainless exhaust for you in about a day (because you never manage to pull one of these jobs off in an afternoon)
 

der_nanno

Faster!
Wet 'n' cold overhere...

(enough ranting)

What's the ID of the stock pipes? The overall layout looks rather conventional, but well sized. So with the right mufflers you should be good to make some nice flow...
 

Brodie

Gold Coast, Queensland
Don't be fooled. They are double walled pipes with the ID coming in around 30mm. I will cut one once I am home and get a proper measurement.

My first plan was to run some reverse cone mufflers on the stock pipes but after having a look the system is all welded from flange to muffler tip.
 

der_nanno

Faster!
Unfortunately I have no access to a W800 or otherwise I would have most gladly slapped an exhaust together for you. Even though not entirely my cup of tea, the engine should have some potential...
 

Brodie

Gold Coast, Queensland
Thanks for the offer mate.

I am about 70% ready to just make it my self. Can't justify spending so damn much.

From what I can find on the net a new pipe is worth about 5hp.

Still need to cut a stock header but it looks to be about an inch at the smallest point.
 

Brodie

Gold Coast, Queensland
Thanks mate. It is a great daily that is for sure.

I am still working on it. Slowly. I have been working 6-7 days a week lately, all nights and afternoon shifts. Being in the dairy industry during a drought sure does such. The drought has somewhat broken now though so things are slowly going back to normal and I should get a bit of tinker time. I have decided to sell a few of the parts I have in the shed to help fund the exhaust I am after.
I have been looking at a Zard 2-1 Stainless Conical exhaust. Claimed weight is 2.9kg. So around a 12kg saving. Which would bring the bike ever closer to my sub 200kg dream.
 

Brodie

Gold Coast, Queensland
Been flat out at work due to increased demand because of the virus. Still not getting much shed time without neglecting household duties.

Managed to get out for a ride the other day and was snapped by a photographer. Had to pull over as my mate on the zx10 was low on fuel and we are about to head up mount Beechmont.
 

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Brodie

Gold Coast, Queensland
Changed the original headlight out for an LED unit today. No problem squeezing it into the near empty headlight bucket.

Here is a quick rundown for anyone without the knowledge.

Locate screws on each side of headlight bucket and remove. One on each side towards the bottom.
Do not remove the screw in the headlight ring, this adjusts the angle of the reflector.
Remove the reflector assembly from the bucket. There is a small clip at the top, gently pull the reflector downwards to unclip.
Remove the plug from original light, remove the dust boot and remove light from the socket.
Install new LED light bracket, reinstall the dust boot and install the light into the bracket.
Plug the new LED harness into the old h4 plug.
Reinstall reflector assembly.
Reinstall the two screws on the headlight bucket.
Enjoy increased visibility.
 

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pidjones

Well-Known Member
Nice write-up! I drooled over an 800 last week at our local dealer while dropping off bike show flyers. Really the only thing they had that attracted me. I wish my GL1000s had room in the bucket for the LED heat sinks, but I fear they are too shallow. I have a spare and I'm considering making a hole in the back of it. So.... exactly which LED rig are you using?
 

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