GV650 Exhaust Mod - Alternative Cruisers

Hyosung GV650 Exhaust Modification
An AmishCrackDealer Production
Disclaimer: - This modification is performed against the recommendations of the
Hyosung motorcycle company and may void your warranties. The instructions are
provided as a free service and by no means is the author or any website that posts them,
responsible for injury or damages resulting from the directions. Perform this modification at your own risk.
1.
Begin by removing the stock exhaust muffler:
· The easiest way to do this is to first removed the heat shield over the “y” shaped pipe in front of the
muffler. There are 3 small bolts (1 on top, 2 on bottom) that hold it in place.
· There are four small bolts that bold the muffler to the “y” pipe flange. The bolt closest to the swingarm and closest to the ground is the one to remove first. It will require several small turns to remove it.
The others can be removed in any order. (Save all bolts and mounting hardware – you will need it for
the installation of the modified muffler).
· Then remove the 2 large bolts that secure the bottom of the muffler to the support bracket. These bolts
use a 12mm wrench or socket.
· The muffler should slide away from the “y” pipe flange, leaving a small “crush gasket” on the flange
pipe. This will be used for the installation as well and may remain on the flange if desired.
2.
With the muffler removed:
· Remove the end cap of the muffler by unfastening the 6 small bolts inside the end cap – they are
visible from the exhaust opening.
· Measure 6” from the back of the exhaust to the front. 6” should be near, if not exactly, in line
with the end of the Hyosung stamp on the pipe. Using painter’s tape, wrap the tape around the
muffler at the 6” mark. The tape will keep the chrome from scratching and keep the cut edges
crisp.
· Using a metal (fine cut) blade, saw the muffler at the 6” mark straight thru the pipe. Take your
time and make sure your line is straight.
· Discard the piece you just cut off – it wont be put back on. (It will make a nice pencil bucket or coin
jar – ha-ha)
3.
After the end of the muffler is cut off:
· You will see 3 internal small pipes. 2 of these pipes go into a visible “chamber” and connect to nothing. The bottom pipe is slightly bent upward and double-walled. You need to either grind or cut these
inside pipes ¾” below the edge of the muffler can to allow the end cap to be repositioned.
* If you are installing a chrome trim basket, you will need to “notch” the inside edges of the
internal pipes. This can be done easily with a cut-off wheel and doesn’t need to be smooth or particularily straight. It won’t be seen. The notches should follow the edges of the exit port of the end cap
and be about 3/4” deeper tahn the rest of the internal pipes.
· Next, you will need to compress the muffler’s internal baffling ( a soft insulation-type material between the
outer chrome shield and the internal screening material). To do this, use a hammer or rubber mallet and tap the
metal screening from inside; try to compress the metal screening and the insulation material as much as possible.
· Place the end cap on the muffler, over the cut line. Make sure the baffling material is compressed enough for
the end cap to fit on the pipe. Use a rubber mallet or other soft pressure to ensure the end cap is secured. The exhaust port will be partially covered. This creates back pressure necessary for clean operation and making proper
low tones that are desired.
4.
With the endcap in the position you want it to be in, drill 3 small holes, equal distance around the edge
of the endcap and into the muffler’s outer shell. These holes will allow you to fasten the end cap using stainless
screws. If you choose to weld the endcap on, you should do it from the inside of the exit port and not the exterior edge of the endcap. The weld will ruin the chrome finish and lead to a possible rust issue later. If you choose
to weld the endcap on, you should skip the next step.
5.
To finish up the look of the modification, you can install a chrome sink drain basket available from almost any local hardware store. They are available in a variety of chrome finishes or designs, so choose what you
like and what is available to you.
6.
Reinstall the new modified muffler in the same fashion as you removed it. This time, the flange bolt that
was removed first, will be the last one installed.
7.
8.
Start the bike, rev it a few times to blow out the dust particles and debris from the cutting and welding.
Enjoy and ride safely.
(This material is the sole work of the AmishCrackDealer. Any reproduction or re-distribution without the express written consent of the AmishCrackDealer will result in the fatal torture of most of your relatives and the
dissemination of illicit material depicting you committing vile and illegal acts with select barnyard creatures.)