replacing air box with pods and exhaust change?

Hello,

I would also love to rip out the air box and put pods behind the carbs but after spending the last two hours of reading up on it it seems futile! I hear a lot about rejeting and problems with this. If I put pods on will I have to rejet? Same for exhaust, my current exhaust is rusting and looks like an old blunder bust rifle. So I would like to put new exhaust on. There is a clamp half way down the pipes by foot pegs, I was wondering if I could remove the exhaust back from that point and put something new on or would this also require rejeting? Here is a pic of my exhaust.

 

Instruction manual for switching to pods:

1. DON'T
2. Refer to #1

 

Is this because of rejeting?

 

And what about the exhaust? Can I get away with changing it out after this clamp in picture?

Thank you for your help

 

Ok, now that THAT is out of the way--

The exhaust pipes connect to the front of the collector box. There are four bolts and collar clamps (one for each pipe). From there on back to the beginning of the mufflers is what is called the collector box. Two more bolts/clamps are used to connect the mufflers to the collector box. The whole system can be removed and each part can be replaced. You will risk breaking an exhaust pipe collar stud, but if your four pipes-to-collector joints are that rusty, you may have no choice.........it may take a lot of kroil, heat, etc.... to get the pipes removed. There is a copper/fiber gasket in there that will most likely be quite stuck. Time and determination will get the pipes out, frustration won't help.

Dave F

 

I'm going to send you a "conversation", too. Check your inbox......

 

It's because the stock system just happens to be engineered to deliver the best performance from the engine in its stock form.

 

Hi... As per your phone call, since your bike is a 650 maxim, you do not have a collector box. Your system is the same in the front but is different from the center on back:

You have:
4 separate exhaust pipes, they can be separated via the bolt/clamping collar/gasket at the bottom of each pipe

Those 4 pipes bolt into the two "y" pipes. These two " pipes connect to each other via a crossover pipe that has a slip joint in the middle underneath the engine. I think there is a bolt on that too....

Each of the two "y" pipes continues on back and become the mufflers. The mufflers are actually welded onto this part, making the y and muffler ( and chrome shield) all one unit.

You can put a straight 4-2 exhaust system on, but without a crossover pipe you're not going to get the best balance between the left and right halves of the engine. You can balance done of that out with re syncing the carbs.

I think I still have used 4-2 exhaust system here ..... I'll look this afternoon and text you back.

Dave Fox

 

Something else I do not see getting mentioned much in these pods/airbox debates is support for the carbs when the airbox is no longer there. Those carb racks are heavy and the intake boots were not designed to support all the weight, especially when you hang the pods on the carbs. If you are going pods, plan on fabricating support for the rack, at the very least one on each corner, to a close by frame member. If you don't, your carbs will spontaneously re-align themselves when you least expect it.

 

Hmm really good point skip! Next thought about that. The air box and it's boots most likely support half the weight of the carbs

 

Current filter in bike
Filter from advance




I think I'm going stock with the air intake. To much Hassel and to much exposure with the pods out in the open. Water would be very problematic. I went to advance auto to order a new air filter because I believe the one in there now is original! It is absolutely trashed especially when my engine was flooded with oil and gas. Oil was actually all the way up in the air box it's self so that's not very good for the air filter. But wheni went down to advance they had one they could order direct OEM but it is a bit different looking. There was no dimensions posted on the order screen but it looks like it would fit. Has anyone seen or heard of this filter? The one on the bike now is D shaped and the one I could order from advance is flat on the one side but has a dome Shape on the other side. ​

 

http://www.ebay.com/itm/EMGO-Yamaha...400-/231354242745?hash=item35ddc996b9&vxp=mtr

Or order from Chacal.

The K&N that advance wants to sell you is reusable, but usually requires a rejet (though not as much of one as pods do, and it's a straightforward process in comparison).

 

I have an '83 xj550 maxim that ran well with pods and open collector and stock jets (112.5 main and 35 pilot). and my carbs never fell off. I just cleaned and did a semi rebuild on carbs and went to 117.5 mains and 37 pilots with stock mix screw setting 2 & 3/4 out, and a bench synch and she runs great. I've ridden in pouring rain without any problem and also most often leave my bike out in the rain although I think I should shield the pods from thatr,