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January 31st, 2012, 02:17 PM   #1
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Rerouting the entire FE450 Stock Exhaust system?

Looking to reroute the exhaust piping similar to the Husaberg Rallye Racing Australia bikes. Anyone else done this? Pros and cons?

[attachment=0:1kxd64x7]aus ralley right side.jpg[/attachment:1kxd64x7]
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February 1st, 2012, 12:41 PM   #2
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Re: Rerouting the entire FE450 Stock Exhaust system?

I would think that the bracket that lowers the arrester would be a weak point and the straight pipe being a weak point too, if you dropped it hard on its back half it looks like you could bend in right into your tire or break something easily. im no engineer but thats my thought....i would think the factory exhaust is bulletproof aside from the heat under the tank area and in my opinion has a cleaner appearance.
And so you dont think im Mr. Negative, a pro would be that it is easier to work on or remove the exhaust system, and would get the heat away from under the tank...
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February 1st, 2012, 04:18 PM   #3
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Re: Rerouting the entire FE450 Stock Exhaust system?

I'm mainly trying to reduce heat. It's difficult enough trying to keep the engine from blowing coolant without the exhaust adding to the heat problem. I'm looking at as many ways to cool this thing as possible.

Apparently the Dakar racers aren't that concerned about pipe damage with this lower layout. I agree, if you flip the bike, it's certainly possible to smash the muffler. But I overheat way more times than I flip the bike.
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February 1st, 2012, 04:35 PM   #4
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Re: Rerouting the entire FE450 Stock Exhaust system?

The other plus with the rally system over the stock one is that it adds 5kph top speed and more through the whole rev range

BUT yes it is more prone to damage if you bin it, and the header pipe by the footpeg gets a very hard time from rocks etc
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February 1st, 2012, 05:02 PM   #5
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Re: Rerouting the entire FE450 Stock Exhaust system?

If heat would be your main concern than i can see how the pros could out weigh the cons for you, you can always beef up its mounting system if needed, better flow and more power would be a double plus, and on top of that it looks way easy to do, go for it!
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February 2nd, 2012, 04:32 PM   #6
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Re: Rerouting the entire FE450 Stock Exhaust system?

Gazza,

I'm planning on using the stock Husaberg muffler. I expect it to be somewhat more prone to bending, but not much. I am going to extend the skid plate further back under the exhaust pipe.

Why did your team choose that exhaust routing? Would having the exhaust damaged during a stage cause major problems? I see others are also using this exhaust routing.

[attachment=0:3ka6z0o4]381686_10150542341516289_315347661288_10757630_132 6596302_n.jpg[/attachment:3ka6z0o4]
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February 2nd, 2012, 04:41 PM   #7
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Re: Rerouting the entire FE450 Stock Exhaust system?

2 key reasons why we ran a low system this Dakar

1) extra large 15L fuel cell on the back used the space where the stock muffler goes

2) to get heat away from the engine

the extra benefit was better top speed (+5kph) and general performance

our bashplate was a far back along the header as we could go, any further and the bashplate will not pivot down to take it off as the rear extension will hit the frame/header etc
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February 2nd, 2012, 06:50 PM   #8
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Re: Rerouting the entire FE450 Stock Exhaust system?

Ah ha. I see how extending the skid plate would be a problem. Thanks for that info.

Tom
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February 3rd, 2012, 06:25 AM   #9
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Re: Rerouting the entire FE450 Stock Exhaust system?

You could easily do a low header pipe set up, whilst keeping the muffler in it's std place. It just requires a bit of thought, / Squiggling of the header, up to the std muffler.

Obviously, it's more involved than the relatively straight shot back to the relocated muffler, but it's hell of a lot less bends than the std header/ secondary has.

A decent pipe builder, would have little problem sorting it out for you. It's just a matter of stumping up the money.
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February 4th, 2012, 09:57 AM   #10
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Re: Rerouting the entire FE450 Stock Exhaust system?

I have been sketching an under engine skidplate/exhaust all in one that goes under the engine up through the hole in the rear swing arm mount and connects to the std exhaust. By building the skid plate and exhaust in one you can make the bottom plate 1/4" aluminum or stainless, incorporate a flattened box expanded chamber in the skid plate directly under the engine (aka powebomb style) and have the internal flow narrow back down to the outlet at the end of the skidplate and attach to the exhaust pipe and bends up behind the brake master cylinder then up tot he exhaust pipe. Notch the skidplate for easy oil changes.

You would lose about 3/4" of ground clearance in my design, but the heat would be away from your boots, fuel tank, legs, and have one sturdy skid plate.

The other design I am considering is splitting the header pipe into a Y pipe as it exits the engine into two smaller pipes and locate theose pipes under the engine and up through the rear swing arm hole. Split the exhaust flow level into two smaller similar flow pipes to prevent changing the backpressure to much. Add a modified aluminum skid plate and go ride.
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