Anatomy of a Hayabusa exhaust system

[Zrex1200]

Loving this thread Camel. I've got a second set of cans that I want to modify, but haven't decided on what to salvage yet. I want to keep the stock appearance but go for maximum flow. I've seen Festers work, and it's sort of what I had in mind.

I currently have made the cans 'straight through' by using a 50mm holesaw on an extended arbor to drill through the partition plate inside the inlet. The outlet pipe is still quite narrow though, and I need to butcher the cans to remove it.

My thought is to remove all internals and fit a 50mm tube from entry to exit. No perforations. No silencing material. Will be fairly loud but look entirely stock (even plan to re-weld screws on end caps). Only a Busa owner might notice the absence of small pipes in the muffler outlets.

The idea of using just one muffler for exhausting and using the other for laughing gas gives me a funny feeling in my pants. I love it!

TempOzzy, that is going to be horrendously loud & probably only useable on a dragstrip.

I am running a 11" long 21/4" baffle with 2" outlet in the Kerker Megaphone on my ZRX & it is f'in loud when on the gas. Pass a car @ full noise & look back to see them swerving all over the road, I try to avoid this...usually.


OEM Kerker baffle & my new custom job


Difference in diameter



Much shorter than OEM Kerker



Spun up the new end cap myself from billet aluminium


Above mods gave me 0.4 sec 1/4 mile improvement over a full length Carbon straight thru can, well worth the effort. Obviously had to richen all jetting to match also.

Since these original photo's I have heavily drilled the perf pipe to quieten it further. I had a complex as I was living directly across the road from a , & cracking this into life @ 6 am was getting nerve racking for me.


Your bike & your choice but I think you will end up not really wanting to ride it on the road due to the noise level.

Whats life without a few social experiments .