Thoughts on mounting exhaust on stock header?

I just bought an XR's Only exhaust for my XL600R and it is a bit larger than the stock header.

I just had to patch my old rusted pipe that connects the muffler and header with Tiger Patch. You put a piece of tin over the hole, wrap it with this stuff, run the engine for 20 mins., it melts down and then hardens.

Since the gap is so wide between the new muffler and header, I plan to cut the old tailpipe section to put over the stock header, wrap it with some Tiger Patch, then wrap it with some tin, still more patch over that, then mount the exhaust and clamp it.

Does this sound stupid to you? Anyone have any experience with this?

you could just try packing it with extra fiberglass

You should just breakdown and buy the xrs only silencer too :bonk: I meant to say header!

I don't ride on dirt, just the city. I prefer to be louder.

The xrs only silencer is a 100db exhaust without the quiet core insert. Thats pretty darn loud! But with header you have a rust free, matching system and will boost your bottom end too!

The XrsOnly "Silencer" is an oxymoron in this context. I think you can tune the sound level on that one by reducing discs.

Is there a HP gain with it?

The XrsOnly "Silencer" is an oxymoron in this context. I think you can tune the sound level on that one by reducing discs.

The new one is not a disc system. I think they came out with them in 03 or 04. I have a full system on order and they are still on back order. I was told they should be in tomorrow. I was told that last week and the week before that too. From what I have researched this is the pipe for a 650l. I will let you know when I get it I have heard from someone on this thread they are worth the wait.

The xrs only full stainless system is the Best you can get, and the latest incarnation does not use discs, and is rated at 100 db, with the quiet core insert 96 db. I would be willing to wait awhile for the best exhaust out there, the quality and design is second to none, fit and finish is awesome, power gains probably on par with other exhausts, but the durability factor makes it the best! My 2 cents :bonk:

Whiteman, next time you call them ask for Kamell he will tell you straight up when you will get your exhaust!

That stuff that you are using to patch up the exhaust, or in this case make a spacer/gasket will only last a little while. The high temp and vibration will kill it pretty quickly. If you really want to use the undersize header pipe you should take it down to a muffler shop and have them weld a piece of pipe on the end of it that will match the I.D. of your new silencer. It will probably only cost 20 bucks or so and you won't have to screw with it again. Or, you could double up on the compressable gasket that belongs there anyway, that might be too much though. Just a thought.....:bonk:

That stuff that you are using to patch up the exhaust, or in this case make a spacer/gasket will only last a little while. The high temp and vibration will kill it pretty quickly. If you really want to use the undersize header pipe you should take it down to a muffler shop and have them weld a piece of pipe on the end of it that will match the I.D. of your new silencer. It will probably only cost 20 bucks or so and you won't have to screw with it again. Or, you could double up on the compressable gasket that belongs there anyway, that might be too much though. Just a thought.....:bonk:

This is the way to go if your not going to get the header. I've got the full system and it is every thing rebel says it is.

They don't make the header for the XL600R anymore. I would've bought one if they did. According to XR's Only they sold me the last exhaust for the Xl600R they had.

I actually mounted it today but used a different method. I used a small sheet of metal mesh to wrap the header and covered that in muffler cement which is almost like mud. It seemed to work rather well. I will let you know if it holds up.

I will post some photos tomorrow.

This is the way to go if your not going to get the header. I've got the full system and it is every thing rebel says it is.

Thanks for the vote of confidence Goblin. Thats funny I have a friend that just purchased the full system for the xr600R. Check with Kamell at xrs only he will give the straight scoop on the availability of the header! :bonk:

XL and XR's are different. They aren't compatible.

This thing sounds like a monster now!

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