Hey guys! Are you looking to boost the performance and sound of your Y15ZR? Modifying your exhaust can be a game-changer, and one popular method is the 35mm exhaust cutting modification. This guide will walk you through everything you need to know about this mod, from understanding the basics to performing the cut safely and effectively. Let's dive in!

Understanding the Y15ZR Exhaust System

Before we get into the nitty-gritty of cutting, let's understand the Y15ZR exhaust system. The exhaust system plays a crucial role in your bike's performance. Its primary function is to expel exhaust gases from the engine, but it also affects the engine's power output and sound. The stock exhaust system is designed to meet emission standards and noise regulations, which often means it's not optimized for maximum performance. This is where modifications come in. By altering the exhaust, you can potentially increase horsepower and torque, and give your bike a more aggressive sound.

The components of the exhaust system typically include:

• Exhaust Header: This is the first part of the exhaust system connected to the engine. It collects exhaust gases from the engine cylinders.
• Mid-Pipe: Connects the header to the muffler.
• Muffler (or Silencer): This reduces the noise produced by the engine. It contains chambers and baffling to dampen sound waves.
• Catalytic Converter: This reduces harmful emissions. (Some aftermarket exhausts may remove this.)

When considering an exhaust modification like the 35mm cut, it's essential to understand how these components work together and how the modification will impact the overall system. The 35mm cut primarily affects the muffler, altering its internal structure to change the exhaust flow and sound characteristics.

Why Choose the 35mm Exhaust Cutting Mod?

So, why should you consider the 35mm exhaust cutting mod for your Y15ZR? This modification has gained popularity for several reasons, mainly due to its balance of performance enhancement and affordability. Unlike purchasing a full aftermarket exhaust system, which can be quite expensive, the 35mm cut is a cost-effective way to achieve noticeable improvements. Here's a breakdown of the advantages:

• Improved Exhaust Flow: The 35mm cut typically involves removing a portion of the internal baffling in the muffler. This reduces backpressure, allowing exhaust gases to flow more freely. Improved exhaust flow can lead to increased horsepower and torque, especially in the mid-range and top-end of the RPM range.
• Enhanced Sound: One of the most appealing aspects of this mod is the enhanced exhaust sound. The 35mm cut gives the Y15ZR a deeper, more aggressive tone without being excessively loud. It's a great way to make your bike sound sportier and more exciting.
• Cost-Effective: As mentioned earlier, this modification is significantly cheaper than buying a full aftermarket exhaust system. All you need are basic tools and some time, making it an accessible option for many riders.
• Relatively Simple: Compared to other exhaust modifications, the 35mm cut is relatively straightforward. With the right guidance and tools, most riders can perform this mod themselves.

However, it's important to note that the 35mm cut is not without its drawbacks. It may not provide the same level of performance gains as a full aftermarket exhaust system, and it can potentially affect your bike's warranty. Additionally, if not done correctly, it can negatively impact your bike's performance or even damage the exhaust system. Always weigh the pros and cons before proceeding with any modification.

Tools and Materials You'll Need

Before you start cutting, it's crucial to gather all the necessary tools and materials. Having everything on hand will make the process smoother and safer. Here's a list of what you'll need:

• Measuring Tape or Ruler: To accurately measure the 35mm mark on your exhaust.
• Marker or Pen: To mark the cutting point.
• Cutting Tool: This is arguably the most important tool. Options include:
  • Angle Grinder: Provides a clean and quick cut. Use with a metal cutting disc.
  • Rotary Tool (e.g., Dremel): Good for precise cuts, especially in tight spaces.
  • Hacksaw: A manual option, but requires more effort.
• Safety Glasses: To protect your eyes from flying debris.
• Gloves: To protect your hands.
• Ear Protection: Cutting metal can be loud, so earplugs or earmuffs are recommended.
• File or Grinding Stone: To smooth out any sharp edges after the cut.
• Welding Machine (Optional): If you plan to re-weld any parts after the cut, you'll need a welding machine and appropriate welding gear.
• Motorcycle Stand (Optional): To stabilize your bike during the modification.

Make sure all your tools are in good working condition before you start. Safety should be your top priority, so don't skip on the protective gear.

Step-by-Step Guide to Performing the 35mm Cut

Now, let's get to the actual cutting process. Follow these steps carefully to ensure a clean and successful modification:

1. Prepare Your Bike:
   • Park your Y15ZR on a stable surface. Use a motorcycle stand if you have one.
   • Allow the exhaust system to cool down completely. Never work on a hot exhaust.
2. Locate the Cutting Point:
   • Identify the section of the muffler where you want to make the cut. This is typically near the end cap.
   • Use the measuring tape or ruler to measure 35mm from the desired point.
   • Mark the cutting point clearly with the marker or pen. Make sure the line is straight and even.
3. Make the Cut:
   • Put on your safety glasses, gloves, and ear protection.
   • Carefully begin cutting along the marked line. If using an angle grinder, hold it firmly and maintain a steady hand.
   • If using a rotary tool or hacksaw, take your time and ensure the cut is clean and even.
   • Avoid applying too much pressure, as this can cause the cutting disc to bind or break.
   • Cut all the way around the muffler until the section is removed.
4. Remove Internal Baffling (If Necessary):
   • Depending on the design of your muffler, you may need to remove some internal baffling to achieve the desired exhaust flow and sound.
   • Use the cutting tool to carefully remove any obstructions inside the muffler.
   • Be cautious not to damage the muffler's outer shell.
5. Smooth the Edges:
   • After the cut, the edges of the muffler will likely be sharp and uneven.
   • Use a file or grinding stone to smooth out these edges.
   • This will prevent injuries and ensure a clean finish.
6. Re-Weld (Optional):
   • If you removed a significant portion of the muffler or want to reinforce the cut, you can re-weld the parts back together.
   • This step requires a welding machine and appropriate welding skills.
   • If you're not comfortable welding, it's best to leave this step to a professional.
7. Reinstall the Exhaust:
   • Once you're satisfied with the modification, carefully reinstall the exhaust system on your Y15ZR.
   • Make sure all bolts and clamps are tightened securely.

Safety Precautions

Safety should always be your top priority when performing any modification on your motorcycle. Here are some essential safety precautions to keep in mind:

• Wear Protective Gear: Always wear safety glasses, gloves, and ear protection when cutting metal. This will protect you from flying debris, sharp edges, and loud noises.
• Work in a Well-Ventilated Area: Cutting metal can produce fumes that are harmful to your health. Make sure you're working in a well-ventilated area to avoid inhaling these fumes.
• Use the Right Tools: Use the appropriate cutting tool for the job. Using the wrong tool can be dangerous and can damage your exhaust system.
• Take Your Time: Don't rush the cutting process. Take your time and make sure each cut is clean and precise.
• Be Aware of Your Surroundings: Make sure there are no flammable materials nearby when cutting metal. Sparks from the cutting tool can ignite these materials and cause a fire.
• If in Doubt, Seek Professional Help: If you're not comfortable performing the modification yourself, it's best to seek professional help. A qualified mechanic can perform the modification safely and effectively.

Fine-Tuning and Adjustments

After performing the 35mm exhaust cutting mod, you may need to make some fine-tuning adjustments to your Y15ZR to optimize its performance. Here are some things to consider:

• Carburetor/Fuel Injection Adjustments: Modifying the exhaust system can affect your bike's air-fuel ratio. You may need to adjust the carburetor or fuel injection system to compensate for the changes in exhaust flow. This can involve adjusting the air-fuel mixture screw on a carburetor or remapping the fuel injection system using a tuning device.
• Spark Plug Inspection: Check your spark plugs to see if they're running too lean or too rich. A lean condition can cause engine overheating and damage, while a rich condition can cause poor performance and fuel economy. Adjust your bike's fuel system accordingly.
• Test Ride and Listen: Take your Y15ZR for a test ride and listen carefully to the engine. Pay attention to any unusual noises or performance issues. If you notice any problems, address them promptly.
• Consider a Dyno Tune: For optimal performance, consider getting your Y15ZR dyno-tuned by a professional. A dyno tune can fine-tune your bike's fuel and ignition settings for maximum power and efficiency.

Conclusion

The 35mm exhaust cutting modification can be a great way to enhance the performance and sound of your Y15ZR without breaking the bank. By following this guide and taking the necessary safety precautions, you can perform this mod yourself and enjoy the benefits of a more aggressive-sounding and better-performing bike. Remember to take your time, use the right tools, and always prioritize safety. Happy riding!