Cheap, redneck exhaust mod for Yamaha G22 Pics & Video

cohocarl

I couldn't stand not being able to hear the engine on my G22, and don't want to pay $300 for an aftermarket one. (and very, very few out there)
.
So I thought I'd cut off the pinkie sized stock outlet & weld it shut, cut a hole in the bottom of the muffler, weld in a 90 degree bend 2" exhaust, then a 2" straight exhaust out the back, (yes, 2" is way overkill, but I already had it in my barn), and fab up a bracket to support it off the rear shock. If it didn't work, I could always cut off the block off plate and weld the pinkie back on and weld a plate over my 2" hole. But luckily, I think it worked out great.:)

First, I removed the wrap around the two long nuts that hold the header onto the head, and loosened them up. (I was worried they would be corroded on, but they were remarkably clean and easily removed ), then removed the bolt on the bottom of the muffler that supports it to the frame. (when re-installing the header bolts, put a dab of anti-seize on the studs first)





After holding the 90 and tail pipe up and getting an idea of how it may work, I removed the muffler, then cutoff the old outlet and drilled a bunch of holes where I had marked the 90's location with a sharpie, then put a cross cut in the area to be removed with my 4 1/2" angle grinder that has a cutoff wheel on it. Then worked the pieces out with a pair of pliers.





Here's a couple pics (the best shot I could get, then adjusted in photoshop to bring out the detail) of inside the 2" hole in the bottom of the muffler. I don't know if you can see the innards, but it looks like the muffler has a divider in it about 1/2 way down. Exhaust from the top 1/2 comes into the bottom by way of a pipe coming down with a bunch of holes in it. You can see this in one of the pics. If I would have known this, I would have made my hole about 1/4" more towards the original outlet. The position I made mine made interference with the 90 I was pushing up in there. I also had to cut off about 3" off the 90 that I was putting into the bottom of the muffler because it was bottoming out on this divider between the top and bottom halves of the muffler.





Before I started welding things up, I put the muffler on loosely and mocked it up as well as I could, and made a bracket out of a piece of angle iron which bolts to the bottom of the shock.



When I had the hole ground out good enough to move the pipes around so they weren't hitting anything, and a slight cut/bend/weld to the straight pipe to get things lined up well, I tack welded it up on the cart, then removed it and finished welding it up. (I know, I'm a terrible welder...) I put some anti-seize on the studs that bolt the header to the head when re-installing.



Here's a pic of it from the rear end of the cart. I have a fart can tip to put on it, but I need to remove the exhaust and put another cut/bend/weld right at the tail end of the pipe so it angles down enough to not hit the panhard rod when suspension compresses.

This picture is hyperlinked to a video on Youtube that I made after I was done. This was the first video I've taken with this camera and I'm amazed how well it picked up sounds. I can hear the stereo in my barn that was very low, and cars driving by on the road which isn't very loud. So I think in the video it sounds a little louder than in person.
But, I think it's perfect. I think I lucked out on this "Carl idea".
I'd compare it fairly close to as loud as my stock Suzuki KingQuad 450.

Down the road, I will try to make a couple more videos and post.

BGW

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cohocarl

Here's a video clip of a short ride with the exhaust.

93yellowclubcar

The real question: did it do anything for performance? Also, excellent throwback to 1981.

cohocarl

81!!! I was hoping for closer to 71!!

RE: performance... Unknown. According to my phone gps, I had a top speed of 11.9mph before. Last night it was 14mph. BUT....I had also installed a new belt and white spring on 2ndary clutch (which I think hurt top speed at first until it broke in the clutch's sliders where they mate). A change in 2mph could have been to a tail wind, weather conditions, or how much I had to eat. To get a noticeable performance gain out of a 357cc 4 stroke, you're looking at having to change the camshaft, raise compression, bigger carb & intake, along with a free flowing exhaust.
But....the main thing...it sounds faster.

93yellowclubcar

Sounds faster...

The cart: throwback to the 70s no doubt.

Journey on the radio: 80s for sure.

cohocarl

That's what was on the radio, but I don't really care for that new stuff...

Quinn

Sounds good! Not too loud but good tone.

duramax

white springs def hurt top end as they are too stiff to compress all the way & let clutch open up all the way. I did black spring, gov mod .new jets & new belt . gps 31mph flat land 13mph up steep hill