Yoshi Exhaust

[DEEARRZED]

Hi all, this may seem stupid but has any one had any troubles fitting Yoshi exhaust sytem to their DRZ400SM.
Long story short i originally fitted a RS3 Yoshi slip on pipe and have now decided to go the hole hog. In order to do this (the unconventional way) i had to buy a yoshi header pipe (of course) and also a Yoshi mid pipe to suit.

The issue is;

1) When bolting the headers on (without using a gasket in the exhaust port) the headers still move when done all the way up. When using the original gasket (which im unsure whether i should use or not) the gasket seems too thick and the bolts wont do all the way up without putting too much undue stress.
2) The rear foot peg exhaust mounting bracket also doesnt line up.. :wtf:

Is there a simple explenation for this or am a just stupid
:withstupid:

[Wobbly]

Do you have a DRZ-E or a DRZ-SM? They S/SM has a different exhaust mounting bracket location than the E does. So you need to make up a little relocator brackety thing.

Is the header gasket you're using a crush gasket?

[DEEARRZED]

I have a SM and the gasket i am using is the original one from the factory exhaust header. When you say i have to make relocator bracket for the foot peg bracket is that what always has to be done or have they supplied me with a 'E' mid pipe??

[Wobbly]

I'm not sure if there are multiple mid pipes for E and S or whether the fully system is only designed for the E. But in any case, maybe give them a call and see whether they have an alternative part# for the S/SM.

Have a search on thumpertalk as well - there are a fair number of (probably fairly old) threads on mounting E exhausts on S model DRZ's.

In terms of the exhaust gasket, it should probably be a crushable type. When you fit the header can you get the nuts on the theads of the studs cleanly?

[DEEARRZED]

Yeah, still plenty of thread poking through for the grabs. Dont think that gasket is crushable though because it all binds up soon after pressure is applied to gasket. Not much movement at all..
Might have to confirm part numbers though, I have a funny feeling it may be wrong.. it just doesnt seem right...

[Wobbly]

As long as you can torque down the header on the studs with good contact with the thread I wouldn't worry too much. The gasket is supposed to provide a seal from the head to the gasket and the gasket to the flange on the header. I wouldn't try and torque it down more than you would with the standard header though.

[DEEARRZED]

I know what you mean but i think the gasket may be too thick. I can get tension in terms of contact with the head, seal and flange but the bracket which is applying the force doesnt butt up against the head like it should.

[Wobbly]

Seriously, I wouldn't worry about it contacting the head - its better that it doesn't, as it means that all the force is applied to the gasket rather than it butting up against the head and not providing any decent clamping force. I've had plenty of bikes that don't...

[Muzzard]

The collar on the Yoshi header will be a couple of mm longer no doubt than the Factory one.
Its to allow for forcing cones to be inserted and still have enough metal to not spread the pipe as you tighten it.
The flange ring should not touch the head on any bike IMO as it is a heat spot and concentrated heat could / can cause problems.

[DEEARRZED]

Gotchya, now it make sense, I was under the impression the flange ring should butt up against the head.. I did notice the collar was a few mm longer and thought maybe a thinner gasket was required.
Thanks again for the advise guys :up:
I'll give it another crack and see what happens..

[Muzzard]

Mount the whole system loosely or just firm enough to locate it correctly but with some give for finer adjustment.
Once your happy that it clears all the bodywork and necessary stuff tighten it up.
If the mid pipe mount is out of alignment there are aftermarket alloy CNC brackets to replace the pillion footpeg mount and also relocates the hole.

[Wobbly]

Not sure if there is an after market relocator bracket for mounting DRZ-S exhausts on a DRZ-E, but if you have some 3mm alloy plate, a vice, a hammer and a drill then its pretty easy to make one up.

[Wobbly]

11: So, I got a screaming deal on a Yoshimura exhaust pipe for an E model will an E exhaust system fit my S?

A: Yes,, The E pipe will fit the S, except for the mid pipe mount. If doing away with the rear pegs, most find then can use the lower peg mounting hole to fit the mid pipe mount to. Due to differences in bikes, trail damage, and pipes,, some have found these two point would not line up, and had to make a bracket for this to work. It is not recommended to run with out the mid pipe mount in place.

[Wobbly]

http://i133.photobucket.com/albums/q64/Skidder1/Picture038.jpg

[Wobbly]

And another...

http://www.gleba.co.il/Gleba/Forums/Attachments/exhaust002.JPG

http://www.gleba.co.il/Gleba/Forums/Attachments/exhaust003-1.jpg

http://www.gleba.co.il/Gleba/Forums/Attachments/exhaust004.JPG

[Wobbly]

Thumpertalk DRZ FAQ:
DRZ400 FAQ - ThumperTalk

Of course the alternative is to ask the guy you bought the header & mid pipe from whether he could give you one for the S/SM, but if they can't then it's not a big job :)

[MarkeeMark]

My Pro Circuit pipe never lined up on my DRZ SM as it was made for an 'E' or 'S' model too. I don't think they make them for the SM. It did however match when I had to get a new rear sub frame which was from an 'E' or 'S'

[Wobbly]

S is the same as SM (but different wheels of course).

E is different to both.

[DEEARRZED]

Ok, I can see this rear foot peg mounting bracket a fairly common issue by the sounds of things.
3 mm alloy plate, here i come...
Cheers for all the info guys :up:

[Muzzard]

;)

[Daws]

...It did however match when I had to get a new rear sub frame which was from an 'E' or 'S'

:oops: once again, sorry about that Mark! :oops:

I was going to mention that Mark's exhaust didn't line up until his bike was customised by me but looks like I'm too late.

Some quality peices of bracketry on the previous pages!

[SMC690]

A mate isn't a true mate until he has thrown your bike down the frog & toad. ;)

[DEEARRZED]

Hey guys, just thought i'd let ya know the Yoshi pipe install was a success with a few minor adjustments.. :chainsaw: :lol:

[DEEARRZED]

Oh, by the way took it for a spin and was quite impressed with the power gains, seems to have more mid to top end. Next job on the 'to do list' a 39mm FRC carb. :roost:

[Wobbly]

Yep, the full yoshi works well due to the tapered header. That's why the only exhausts worth worrying about on the DRZ are the yoshi, the muzzy (basically a copy of the yoshi) and the FMF...