Dakar / Sertao exhaust Mod

[MickDB1]

Hopefully this may help folk save a bit of dosh
I recenty cut a exhaust up off a 2005 Dakar. I, with the help of OZs (Advrider forum posts), tapped the small nearside exhaust hole with a 10mm tap inserted some screwed rod and pulled the baffle do dah out - then chucked it !! I then cut the transfer pipe back and blanked it off with a 2" /50mm disc of SS

SOME EARLIER DAKARS EXHAUSTS ARE DIFFERENT OD SO CHECK EXACTLY THE SIZE ( only a mm in it I am told)
Sound great but have not tested it over a long period of time yet - done 200 miles mind
Seems like the cat does nearly enough to keep the " It makes toooooo much noise down folk" happy
Sound just slightly noisier than the original and has the I am a 650Thumper not a washinmachine
Hers some pics
Tried the Dakar "swap the tank mod for 3 lts more fuel storage 17 in stead of 14lts" too = seem OK but not as easy as I thought it would be
More when Ive done a thousand miles to test it
Also fitted the single seat ( which a lovely friend gave me !!!!!
Also a re-site of the regulator bracket I knocked up
Its a S shaped piece of SS the outside hole centers are 205mm the vertical centering is 60mm the paired holes are 68mm centers It utilizes the holes on the placky guard and keeps cable run neat
Hope this helps yer get it out of the way of the suspension adj knob and from behind the sumpguard - and in some air flow
Want some dry weather now
HTHY
Mick

 

[Timolgra]

Nice one Mick, I'd seen the exhaust mod you've done before but never tried it. It seems most of the aftermarket pipes are too loud so this could be the way to go.

I like the single seat and generally keep my eyes open for one ... you jammy sod

What were the problems in fitting the Dakar tank?

 

[MickDB1]

Main problem would be - I was on me own - and second was them stupid BMW wireing connectors that dont like to be taken to bits by village people/idiots
The job took me 3 or 4 hrs as I had to feel me way with what I was doing you could maybe do with another set of arms to release and relocate the rear subframe.Bet yer could it easy in 3 max now
The massive plastic nut on the fuel pump was undone with muscle and BFO rubber gloves
Did 150 on first run before light and trip reset the rundown - I am currently waiting for a dryish day to have a ride and take spare can to see what I get down to before a splutter then do the how much can I get in calc = It should hold 17lts acording to the spec
More as it happens
HTHY

 

[Timolgra]

Did you fit a new seal under 'the massive nut' or use the old one (think I have a spare anyway), and I guess the internals are a straight swop?

The main thing is that it sounds pretty straight forward and that it actually fits without any alterations?

As a matter of interest does the new tank cause you to part your thighs any further compared to the Sertao one?

 

[MickDB1]

The new 2013 tank nut fitted the 05 tank - It measured slightly larger than the old tank but as the rubber joint was a very tight fit (used some wd to lube the fit into the tank) maybe the tank expands/stretches slightly as you insert the pump and gasket ( this was done carefully as I have read of older gaskets being torn = dont think they are much anyway)
The old Tanks are very much the same size - The new ones have a Big bloody hole/space in them for a US carbon filter that the tank vent is supposed to "vent into" to save the calafornians from petrol vapour burp also they have a stremlined slope towards the RHS exhaust muffler = see last picture above and the tank has a squared off front edgeThe exhaust is to become a muffler - toolbox
see underside picture of new tank when removed - This i think is the 3 lts of missing fuelspace - The only difference I see is that the electrics are held in place at front of the tank - on olduns with self tappers and new uns with 5mm SS buttonheads

HTHY

 

[Timolgra]

Good one thanks.

It's probable your fuel light comes on early now then, it'll be interesting to see what the 'real' range is with the bigger tank.

Ange used to get 180+ miles on her single spark Dak before the light came on and has done another 25m with probably more to go so it may be possible to safely rely on a 220 range by taking it steadyish on a Sertao. Good enough for me!

 

[MickDB1]

Tim just about Everyone on the internet seems to get more to the gallon than me !!!
That 150 was nearly all motorway at true 75 mph on GPS and I "filled it" on side stand
I will post proper mileage knowledge when I have done more riding

 

[timeandtide]

Tim just about Everyone on the internet seems to get more to the gallon than me !!!
That 150 was nearly all motorway at true 75 mph on GPS and I "filled it" on side stand
I will post proper mileage knowledge when I have done more riding

That's because you're such a teararse Mick!!

 

[Timolgra]

That's because you're such a teararse Mick!!

Or that 8 tooth front sprocket

 

[MickDB1]

I have actually just got a 15 tooth for the front - but not fitted it yet
I beleave owt under a 14 just wears the chain toooo much
Cant understand the petrol consumption just run steady through the gears and leave it in 4th as much as I can/ or untill the rev limiter kicks in !!

 

[Dansin]

From what I've been told you can adjust the height of the fuel warning level. I've gone the other way and have an 11 litre Elkamet tank fitted and my fuel light comes on after 35 miles as I haven't been arsed to adjust it. .

I haven't run it to empty but I'll happily run it to 120 miles before filling up. I can then usually only get about 8 litres in and that's running a 15t front sprocket. . With the standard tank and 16t front sprocket I'd regularly get 220 miles between fill ups.

 

[dubber68]

Need to sort mine now Mick. Nice to see you are doing the exhaust tool holder idea.

 

[Timolgra]

Ooh look what's just arrived for 20 quid

 

[MickDB1]

Bargain of the week Did yer get the keys as well ??
Locks worth more than that - Jammy git - or well placed astute buyer
Well done

 

[MickDB1]

Need to sort mine now Mick. Nice to see you are doing the exhaust tool holder idea.

I have started that bit but it needs a hell of a lot of chopping and fettling so I gave it an hour and going back to it as there are a few bits inside that dont want to comply with our thoughts

 

[Timolgra]

Bargain of the week Did yer get the keys as well ??
Locks worth more than that - Jammy git - or well placed astute buyer
Well done

There were no keys, I'll just swop the filler or have a fiddle.

 

[MickDB1]

Update on the exhaust mod I did
The emitting sound although OK and not too loud was a bit flaarrpy - I have now put a 16mm ID insert 50mm inside the exhaust outlet
well a 16mm SS washer actually Job is definitely a good un and I am well happy with the result