K8-K9 600/750 Cat Removal & Replacement w/K6-K7 Exhaust

Hong3103 · 07-30-2008, 01:55 AM

(Pulled from another forum)
Well it can be done! You can put a K7 slip on onto an K8 stock header. Here is the how-to with pics!

***Be warned though, you will probably need a custom map & PCIII(or some other fuel management system). You can try some of the maps that is provided by Power Commander but aren't guranteed to work.***

1. Remove both side fairings to access exhaust and CAT.

2. Use either a cutting wheel or a hacksaw to remove the CAT right up against the weld. I had to use both because the wheel wore down on me, the yellow is from the hacksaw blade.

3.Once the CAT is out of the way put a small bevel on the edge of the header, you will need to do this the help get the mid pipe up onto the header. It will fit but it may require a little elbow grease. I had to put a 2x4 against the back of the mid can and tap it with a hammer. The 2x4 will keep from damaging the pipe, just dont get carried away with it! Make sure to put the clamp on before you start tapping it on.

4.Make sure to tap it all the way till it touches the weld for the SET Valve. You may have to slide the spring towards you to keep from pinching it but it moves easily with one finger or you can just remove the thing. (http://www.gixxerplanet.com/home/sho...=valve+removal)... you may also want to visit this page if you getting the FI light after doing the mod.

5.From here you can just follow the instructions of the exhaust you bought. Its just like installing on a K6/K7 600/750 from here! The side mounts for the under can on the Yoshi where tough to get lined up but they will so be patient. You really can't tell the difference between a K6/K7 & K8.

Hopefully this helps those with K8's that want to lose their CAT.

ballababy101 · 07-30-2008, 07:56 AM

great post man.... i got 07 headers to put on but if the fi light comes on and other problems i may resort to cutting the ugly thing off...

Hong3103 · 07-30-2008, 11:20 AM

Quote:

Originally Posted by ballababy101

great post man.... i got 07 headers to put on but if the fi light comes on and other problems i may resort to cutting the ugly thing off...

I'm willing to bet you that your FI light is caused by the SET Valve. Did you remove it without pulling out the pin in the ECU? If so check out this page... http://www.gixxerplanet.com/home/sho...=valve+removal

ballababy101 · 07-30-2008, 12:29 PM

ah i aint gonna full w/ it i got a jardine gp1 on my bike for now... imma just gonna wait and save up for a full exhaust system... id like to get a full system two bros v2

jondelicious · 08-04-2008, 04:09 PM

that's exactly what i had done =) the r-55 sounds beautiful on the bike so can't complain

mcgixxer · 08-04-2008, 04:40 PM

Thanks for the post, Hong.

08KB750 · 09-04-2008, 07:24 AM

Excellent Post!!!

US Marine#1 · 09-06-2008, 04:24 PM

guys, just an FYI. I know Ballababy, you said you got the Jardine on your bike. I have that on my 07, and my FI light was coming on. I bet you, just like hong said. Its your set valve. you dont have to take it off, or f*ck with the wiring. take your pipe off, WD-40 the inside, and slide it back on... when you put it back on, do not torque it doen a lot... just snug. it'll help, your light will go off, and hopefully stay off... try it out bro, laters

ANTHONYDM1 · 09-15-2008, 04:51 PM

yooooooooooo now we talking im going to the garage lol

pb125 · 09-23-2008, 07:09 AM

GREAT post! I just got a K8 750 and am looking for this solution. What mapping are you using? How about the warranty for the bike? Is it null once the cat is removed?

Hong3103 · 09-23-2008, 09:07 AM

Quote:

Originally Posted by pb125

GREAT post! I just got a K8 750 and am looking for this solution. What mapping are you using? How about the warranty for the bike? Is it null once the cat is removed?

It shouldn't void the warranty. A full system exhaust doesn't void the warranty on your bike. The dealership/Suzuki would have to prove that what you did cause the damage. Doing this mod won't void your warranty if for example the subframe was cracked because of defective workmanship, this mod won't void the warranty in that sense. Now the AFR (Air to Fuel Ratio) will be a little out of wack. You'll be opening up the air flow so there will be more air than fuel. So it will be leaning out the mixture which in the long run could burn up your valves.... to my knowledge. You will probably need a custom map and PC3 to get the right AFR. You can try to get the maps of Power Commander but they won't be 100% correct.

Sportsfame18 · 09-23-2008, 09:29 AM

is it better to do that, or get an 08 slip on and cut off the cat and get a midpipe

pb125 · 09-23-2008, 12:34 PM

I REALLY don't want to foul up the motor. I was thinking you could install a power commander for that solution. I did find an exhaust maker that eliminates the cat: www.hardrockmotorsports.com I'm figuring that exhaust will also use a power commander. The HR1 doesn't look all that great buuuut.... Bruce Fabrications has a beatiful exhaust but no plans as of yet to produce something for the k8. I'm a little new to FI considering I came from a carbed bike. I just want to put on the right exhaust without blowing a butt-load of cash on a full system but, I suppose that's what I'll have to do. UNLESS your saying a power commander will work optimally with this set-up.

Hong3103 · 09-23-2008, 01:56 PM

Quote:

Originally Posted by pb125

I REALLY don't want to foul up the motor. I was thinking you could install a power commander for that solution. I did find an exhaust maker that eliminates the cat: www.hardrockmotorsports.com I'm figuring that exhaust will also use a power commander. The HR1 doesn't look all that great buuuut.... Bruce Fabrications has a beatiful exhaust but no plans as of yet to produce something for the k8. I'm a little new to FI considering I came from a carbed bike. I just want to put on the right exhaust without blowing a butt-load of cash on a full system but, I suppose that's what I'll have to do. UNLESS your saying a power commander will work optimally with this set-up.

If you're looking for something similar to Bruce Fabrication I suggest you check out FMF http://www.fmfracing.com/default_det...&app_year=2008 they have a slip-on for the K8's.

A PCIII, Bazzaz, or Juice Box (for 2 Bros) will help to keep the AFR at the proper ration. Like I said if you're going to do this frankenstein mod it's probably best that you get a custom map.

pb125 · 09-23-2008, 05:22 PM

I was hoping to avoid putting on a noise maker (slip-on) with little to no Horse power gains. That is why I was intrigued by your "frankenstein" set up. I would be curious what custom map would be available.