homemade PU kit for 08TE510

Finally I made my own Power Up Kit. When I bought my Bike (leftower 2008 model), i didn't do the PU, mainly because its really expensive here. I had tried a TE510 with it and liked it.I have to admit that my bike really was OK without the PU. I had to do a initial ibeat setup at 200 km because of some hesitation. After it it was running really strong
with only a light hesitation at constant throttle at 2400 rpm. I dont know if i was lucky or here the bikes are less restricted (we get for example the open filter cage and no canister). But I still wanted a sort of PU and the idea of modifiing a stock exhaust, to remove the cat was for a couple of weeks in my mind. This way I would be able to remove the O2 sensor and shave some weight on the exhaust. I was able to buy a unused stock exhaust (just in case I ruined mine).

I cutted the stock exhaust on both cap welds, and found a array of baffles and tubes and the CAT. Also a perforated steel plate in the inside. Once open i saw everything needed to build a straigth trough exhaust. So I did some research and did a design with a perforated core of 38mm. I also shortened the exhaust some inches.

After some welding, cutting, riveting I was able to build my own exhaust.
I bought also a 2kohm resistor (10 for les than 20 cents of a US$) and a bronce plug for 3 US$ from a bolt store.

The results are

Weigt loss from 4750g to 2900g ( I know the kitchen scale is not the most accurate) I didnt need the heat shield, because it runs cooler.
It looks Ok to me, but you might judge from the pictures.
On the bike it feels good. Ligther and powerwise better. Honestly not too much power more (at least i didnt notice it), but as stated before my bike really was strong since the beginning. The main difference is the power is smother, and now the bike reacts a los faster to throttle.
Soundwise it got a deeper sound, but not much louder than stock. I run it with the db killer insert, since i dont like loud bikes.
Fuel consumption rised compared to stock, but you can return the O2 sensor really in a couple of minutes if you need it really.

very cool...

Congrats on completing your project.

I'd love to see some riding pics from Chile if you have them online somewhere.

NC

I'm in the process of uploading some pictures. i'll post the link when i'm done

Here is a link where i have some pictures riding in Chile.

Most of them are on my old trusty 98 XR400 (I owned it for 10 Years)

http://picasaweb.google.com/fhornp/MotoPicasa?authkey=Gv1sRgCI3Yod_55-fa-gE&feat=directlink

ChileHusky

Nice job!

How did you get Ricky Dietrich down there?

I had wondered about opening up the stock bazooka myself. No more cat and no more melted turn signal. Priceless. Good job man.

Thats my youngest brother.

He looks really similar

I will tell him, he will be happy