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Exhaust & Mod Shop Looking for the best exhaust for your Kat or need help with the installation ?
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Old 11-14-2018, 02:11 AM   #1
y2ktj
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Default pre exhaust questions

Some of you know I'm a newb and Rebuilding a 1990 600 kat on a budget. Po I believe had a low side incident, something involving a loose rear tire. So the exhaust has been cut off on both sides just after the cross tube. He gave me the slip on muffler off his zx6 that he replaced in case I could use it. Metal work and welding is not an issue for me so I can rebuild it myself. So the question is should (and can) I use the zx6 can and build a 4-1 exhaust or should I just buy 2 new cans. Dont want to rejet the carb but I would have to if I went 4-1 right? And what should I look for in stock replacements? Just looking to get it running so I can ride it, performance is not really an issue. I think I know your advice will be to just replace the stock cans.
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Old 11-14-2018, 07:24 AM   #2
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Quote:
Originally Posted by y2ktj View Post
Some of you know I'm a newb and Rebuilding a 1990 600 kat on a budget. Po I believe had a low side incident, something involving a loose rear tire. So the exhaust has been cut off on both sides just after the cross tube. He gave me the slip on muffler off his zx6 that he replaced in case I could use it. Metal work and welding is not an issue for me so I can rebuild it myself. So the question is should (and can) I use the zx6 can and build a 4-1 exhaust or should I just buy 2 new cans. Dont want to rejet the carb but I would have to if I went 4-1 right? And what should I look for in stock replacements? Just looking to get it running so I can ride it, performance is not really an issue. I think I know your advice will be to just replace the stock cans.
Re-jetting for a 4-1?
Well you can buy a Katana post 97 4-1 stock system including the oil pan and pickup, or a Bandit system. Plenty of Bandit stainless headers usually available on Ebay.
I kinda doubt you'd have to re-jet for a Suzuki OEM 4-1 system. But re-jetting would be kinda EZ and not pricey, as you could just buy 4 new jets for less than $20, and just one size larger. Or just raise the needles a tiny amount.
Mostly you would just need to tune the idle screws and sync the carbs. All things you need to do anyway.

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Old 11-15-2018, 02:47 AM   #3
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I'm a total newb to the mechanics of bikes Bill. I've done a fair amount of riding on a friends 250 mx bike and I have a small 125 mx bike that I have worked on a bit. Cleaned the carbs and basic matinence. More of a pit bike than anything. But street bikes are new to me. I knew that a post header and pan would work for a 4-1 but thought you'd have to rejet as well. A friend of the guy I got the bike from will probably help me rebuild or rejet the carb if I asked. Awesome guy who knows his shit and answered a million of my newb questions. What year's bandit? and do you need to replace the pan with the bandit headers? If I did a post swap will the zx6 can work? After my post did some googling and got the impression that any can will work.
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Old 11-15-2018, 04:51 AM   #4
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If you want any 4-1, you'll need a post '98 oil pan and pick up tube for that pan. To prevent having to re-jet, just buy any post '98 katana 4-1 header. The Bandit header is very slightly larger. Besides re-jetting, I believe I remember reading it requires slight modification to your under belly plastic etc...
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Old 11-15-2018, 07:48 AM   #5
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One worry about other bike headers is, will they clear the Katana front brace across the engine front.
I had to sell a 93 GSXR1100W header, because the down pipes not come forward enough to clear the brace.
I have Katana 1100 headers on my 750 now, and they fit.
The facts about modding bikes or cars is, you will have to buy stuff and find out for yourself if it works. Re-sell the stuff if it don't work.
You'd better have what it takes to figure out solutions to issues.
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Old 11-15-2018, 08:32 AM   #6
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The ZX CAN can be used. It depends on your fabbing skills. The can on my bike was meant for a Yamaha. wish I could find another, for duels.
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Old 11-15-2018, 09:26 PM   #7
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I've been customizing and fabbing every vehicle I've owned since I was 16. From my first car, a slammed Corolla to my 2000 tj. Custom 3 link coilovers, front axle stretched out 5" and built all the armor. Its half the fun of owning a vehicle. Look forward to doing the same to the bike but want to get to know it first. Thanks for all the advice. That's why I love forums like this to lean on the more experienced. Couple pics of my first car and my jeep.



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Old 11-16-2018, 01:11 AM   #8
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Besides your ability to fabricate, I'm not sure if we completely answered your question the way you meant to understand it. I personally would only use stock dual exhaust to keep from re-jetting. Thats not to say you can't use a stock 4-1 made for later model 600-750 Katanas , just as long as you use the stock muffler too. If you use a aftermarket muffler with stock headers, I'd still re-jet just to be on the safe side, but thats just me. This is where I feel we left you hanging unsure. You need to be absolutely positive here, so continue to do research. Otherwise you'll melt your pistons and waste what would have been a perfectly good running bike. I see katanas for sale on Craigslist all the time with swapped exhaust and the seller is like, all that its needed is the carbs need to be rebuilt. When what has actually happened is the motor has overheated a lost compression.
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Old 11-16-2018, 01:23 AM   #9
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My kat is a 99 750...stock 4 into 1 pipes with a yoshimura rs3. Ivans jet kit and stock air filter. I've got no problems since I cleaned and rebuilt the carbs.idle to redline she sings that wonderful song we all love...
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Old 11-16-2018, 01:28 AM   #10
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And, just to take things a bit further, to make your life a lot easier in the future, go ahead and buy a center stand before you attach any type of exhaust , PERIOD
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