high flow sv1000s exhaust headers

[Temporary-Kiwi]

Hi, so my brother has talked me into making him a new exhaust for his sv1000s, I did some calculations and decided on basicly the same size as std diameter, but in a slight tapered style, which ive found gives increased acceleration thru boosting the torque curve, which is what he's asked for, more usable midrange.
so I've just removed the stock exhaust after getting a base dyno run, which showed 109.7 hp/ 66ft lb torque.
I must say the stock headers are terrible, especially the rear header, and all of the tailpipe aren't much better.
so I'm expecting it to improve to around 120hp
but mostly to increase roll on torque.

[AllanB]

Keep us posted. 10hp is big gain to expect just from the exhaust (assume a custom map).

[Temporary-Kiwi]

considering how bad the stocker is, it should be achievable, I am going to retain his yoshi mufflers, and the headers will be separate to each muffler.
yes it will get dyno tuned after, I'm still wondering how to post pics on this forum ?

[nzspokes]

Im surprised at the lack of torque they have. Thought they were torque monsters. Guess not.

[AllanB]

I'm pretty sure I've read on the SV forums a 2-1 punches out good power. Might be worth a troll through their site.

[Temporary-Kiwi]

I'm pretty sure I've read on the SV forums a 2-1 punches out good power. Might be worth a troll through their site.

I did have a look thru there site, it does seem another problem may arise with my previous plan, individual pipes may alter power delivery even at std length.
so i investigated the two - 1 option, it's very tight fitting to get near stock pulse wave length, looks like il have to alter the oil cooler mt to reduce front header an extra 2 inches.
and make a curved collector to get it to fit at 660mm length header.

[98tls]

I'm pretty sure I've read on the SV forums a 2-1 punches out good power. Might be worth a troll through their site.

Can remember a few on the TL site tried 2/1 but no power gains of much note,still got a 2 Bros 2/1 header setup in the shed that i had on the TL years back fwiw.

[98tls]

Have a M4 exhaust on my old S and outta interest went looking for pics of an SV with same,came across this with 2/1 M4 setup,front header doesnt seem any closer than the setup on mine fwiw.
https://i.imgur.com/4DLVST9h.jpg
https://i.imgur.com/iATi2kth.jpg

[Temporary-Kiwi]

Hi, yes I looked at the m4 setup and the yoshi, they're getting around the problem by putting a crossover pipe before the collector, it's a compromise, yet I may have to do simular as it's not looking viable to get headers to join @ collector at the length needed.
he likes the idea of only needing one muffler though, otherwise I could replicate stock style of individual pipes with a crossover pipe.

[Temporary-Kiwi]

Hi, so I've managed to get the headers equal length, made a short curved collector, fitted tailpipe up to one of his yoshi mufflers tonight, in the morning I'll reinstall the shock and give it a test run - then I'll know if I have to install a crossover pipe.
I'll take a couple of pics to post 2moro.
it certainly sounds sweet with the single muffler !

[Temporary-Kiwi]

Hi, so I gave it a run - must say it's seems to going considerably better, more roll on torque, and much better power from 4k up all the way to "redline" , that in particular was poor before, above 8 k it previously felt anemic.
still have to go over it after a couple more runs to inspect for any cracks, as tapered header exhausts run very hot and will fracture any weak weld joints.
then I'll give it some hi-temp paint , while I'm waiting for a spot on brents dyno for some fuel tuning.

[Temporary-Kiwi]

Hi, so I've got sv booked in for dyno tune on Monday
I've just painted the headers, took a couple of pics beforehand
340970340969

[layton]

Looks the part, I have found that an orbital sander will remove and clean up the grinding marks quite well!

[Temporary-Kiwi]

yes i use a flap disc mainly to clean up the welds, I painted it, then remembered I was going to weigh it to see how much lighter it was, took it down town for a new wof, when I got back I See it's burning the hi-temp paint off !
I ordered a k&n air filter on Friday morning, motozone texted me this morning to say I could pick it up, so I've fitted that as well as opening up the snorkel to allow easier access for the air to get in. I checked the spark plugs- white as ceramics, so it's running very lean, be interesting to see what numbers it throws out, I'm fairly confident it's over 120hp @ wheel, but the torque feels much improved, and I haven't reset the cam lobe centers yet....

[layton]

yes i use a flap disc mainly to clean up the welds, I painted it, then remembered I was going to weigh it to see how much lighter it was, took it down town for a new wof, when I got back I See it's burning the hi-temp paint off !
I ordered a k&n air filter on Friday morning, motozone texted me this morning to say I could pick it up, so I've fitted that as well as opening up the snorkel to allow easier access for the air to get in. I checked the spark plugs- white as ceramics, so it's running very lean, be interesting to see what numbers it throws out, I'm fairly confident it's over 120hp @ wheel, but the torque feels much improved, and I haven't reset the cam lobe centers yet....

are they not 120 standard? or there abouts?

[Temporary-Kiwi]

are they not 120 standard? or there abouts?

yes at the crank they are around 118hp, I got a base dyno run which showed 109hp/66ftlb tq, @wheel, mtr had just been serviced and had yoshi mufflers and the tank lift mod which allows cooler air into eng.
if the m4 exhaust system is anything to go by , it should gain 6hp, but I'm expecting 12-15hp from exhaust, + 1-3hp from air filter

[AllanB]

are they not 120 standard? or there abouts?


Crank hp at best. WRHP is what a dyno reads.

[Scubbo]

i changed my oil, expecting 100HP gain right there, that would make the xtz125 108hp at the wheel :eek:

isnt the suspension the real problem with the SV? make it go faster in the corners rather than wasting $$ and reducing engine life of the bike when its not going on the track? >_> anyway goodluck have fun with the build

[AllanB]

i changed my oil, expecting 100HP gain right there, that would make the xtz125 108hp at the wheel :eek:

isnt the suspension the real problem with the SV? make it go faster in the corners rather than wasting $$ and reducing engine life of the bike when its not going on the track? >_> anyway goodluck have fun with the build

Why would a better performing exhaust system reduce engine life? A better system (and fueling) will improve real life riding across the rev range.

[Temporary-Kiwi]

i changed my oil, expecting 100HP gain right there, that would make the xtz125 108hp at the wheel :eek:

isnt the suspension the real problem with the SV? make it go faster in the corners rather than wasting $$ and reducing engine life of the bike when its not going on the track? >_> anyway goodluck have fun with the build

suspension was the first upgrade I advised him to make, and he followed that advice, Robert Taylor upgraded fork internals, and fitted a nitron rear shock.
I also fitted some ebc higher grade brake pads as the stock ones were very wooden and had limited stopping power.

[98tls]

Good work fella,more pics sometime if ya will.

[Temporary-Kiwi]

so the tuner (brent) has been too busy to get to the sv this week, as he has the supersport 300 class on his mind.
so hope it's gonna get done early next week, cause my bike is next to be tuned, been waiting about a month for a spot to get it tuned....

[AllanB]

Must be a good bugger if he is booked out.:2thumbsup

[Temporary-Kiwi]

just pickt up Bretts sv1000, dyno said 121.2 hp, was thinking it was stronger, it is what it is, I managed to get my bike back together and swapped it over for tuning.
it should be getting done next week at last!

[AllanB]

121 at the rear wheel is a decent gain from stock.

[Temporary-Kiwi]

better than a kick in arse, 11.5hp, still waiting on the dyno sheet to See the torque delivery, power curve was fairly progressive, but it gained most in top 1/3rd of delivery.

[Temporary-Kiwi]

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hi, so here's some pics of completed exhaust, I included before /after dyno sheets

[BuzzardNZ]

Either I'm too pissed, or they are all upside down !

[Temporary-Kiwi]

your not the only one, I'm sure they were up the right way when I uploaded them...
so the airbox snorkel mod didn't help and it was too noisey, it was making alot of really loud pulsation reverberation, so ive got him a 2nd hand replacement to get it sounding quieter for the bro.

[AllanB]

The nice progressive link you have made for both headers looks like the set-up on my Ducati. Nice smooth flow.

[BuzzardNZ]

so the airbox snorkel mod didn't help and it was too noisey, it was making alot of really loud pulsation reverberation, so ive got him a 2nd hand replacement to get it sounding quieter for the bro.

I found the snorkel removal mod made a fair amount of difference. but you're right about the extra noise.
Adding all the small mods up and a Teka tune on the dyno made for a better running and slightly more powerful bike from stock.
Mine has TRE, snorkel removal, BMC air filter, 2 brothers pipes. Overall, I'm happy with the bike apart from the crap suspension.

[AllanB]

Overall, I'm happy with the bike apart from the crap suspension.

Nothing money won't fix :lol: Front fork springs to suit your weight and riding are quite cheap and if you are handy on the tools a straight forward job to replace.

[Temporary-Kiwi]

so after running my brothers sv1000s on the hillclimb, I made a couple of discoveries about the suspension package kss installed on it for my bro, it has the wrong springs front and rear, r/shock spring is too hard even for me, and I'm 10 kg heavier than Brett, the f/springs are so soft, it will slam down bottomed out if you grab the front brake hard, and I found the rear spring was set @min preload, and on 1st comp damp setting (softest), fork comp damping is at 3rd stiffest setting, so not much extra adjustments avail, and I had increased the fork preload abit, Brett had already mentioned how soft the f/springs were, so I think he will be talking to them about some changes to the springs

[nzspokes]

so after running my brothers sv1000s on the hillclimb, I made a couple of discoveries about the suspension package kss installed on it for my bro, it has the wrong springs front and rear, r/shock spring is too hard even for me, and I'm 10 kg heavier than Brett, the f/springs are so soft, it will slam down bottomed out if you grab the front brake hard, and I found the rear spring was set @min preload, and on 1st comp damp setting (softest), fork comp damping is at 3rd stiffest setting, so not much extra adjustments avail, and I had increased the fork preload abit, Brett had already mentioned how soft the f/springs were, so I think he will be talking to them about some changes to the springsDid he tell KSS the bike was being setup for racing or street use?

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[Temporary-Kiwi]

it's a road ridden bike, no track time, he rang them yesterday.
it will need a softer shock spring, firmer fork springs, wth the pack rack fitted + 15 kg load it was just about right with me onboard, and I'm 12kg heavier than the bro.
so needs approx 50lb softer spring to suit him, and allow some adjustment.
the fork springs probably only need next stronger rating, as he is lighter, and doesn't ride it hard out, probably 6/10ths pace.

[Temporary-Kiwi]

a replacement shock spring is about to get fitted, plus Kss are going to adjust the hi speed damping internally to remedy the rear end, then they will assess the forks for what they need changed ? probably be after easter