Brozz exhaust

[Hancadam]

Hi everyone.

I put the eBay/Amazon exhaust that everyone buys on my Brozz. Really happy with how it turned out. Fits perfect, but did take some tinkering. I have around 3/8 to 1/2 inch clearance from the air box. Cleared everything else easily. Had to make a bracket for the rear mount.

Definitely helps out with adding a little power.
Sounds great.

https://i.ibb.co/JztgNjZ/IMG-20190417-155807714-HDR.jpg (https://ibb.co/dQMxS4Z)

[Hancadam]

Also, I had to trim more of the rear fender/mud guard out of the way. The clutch lever arm was just a little too close, so I peened the pipe in slightly. Didn't want it rattling.

Price on eBay was $89.

[2LZ]

Sounds about right on the project! Glad you like it!

[Megadan]

Turned out nice. You had some of the typical fitment issues we all tend to have. I got lucky that my head pipe cleared everything on the engine just fine, but if I was planning on keeping my stock air box I would have been SOL. Thankfully I was able to utilize the rear grab handle bolt with a spacer for my muffler mount this time around, but I did have to flatten out a small section near the rear of the frame just to buy it a small air gap. It wasn't touching, but it was close enough I would need a feeler gauge.

[Hancadam]

Thanks 2LZ and Megadan!

I ended up mounting the bracket I made to the rear grab bar bolt as well. It actually mounted up without the bracket, but was then close to the air box. The bracket luckily allowed it to drop into a better position.

I love how it's changing colors with heat cycles. Looks very cool to me.

Also, I removed the smog pump and capped off the air box/intake lines.

https://i.ibb.co/52DcSjL/IMG-20190417-181346342.jpg (https://ibb.co/nR2kY1j)

[tarote9025]

Also, I removed the smog pump and capped off the air box/intake lines.

https://i.ibb.co/52DcSjL/IMG-20190417-181346342.jpg (https://ibb.co/nR2kY1j)

Whats the benefit of doing that? Is it basically an egr delete and allows the notor to run more efficiently?

[2LZ]

Whats the benefit of doing that? Is it basically an egr delete and allows the notor to run more efficiently?

It's not an egr. It's a fresh air injection into the exhaust port to toss fresh oxygen on the hot cat to help it do its job. Once the cat is removed (new exhaust), that air injection will be tossing fresh oxygen on your new muffler packing.
Best to disable it if you remove the cat.

[NzBrakelathes]

It's not an egr. It's a fresh air injection into the exhaust port to toss fresh oxygen on the hot cat to help it do its job. Once the cat is removed (new exhaust), that air injection will be tossing fresh oxygen on your new muffler packing.
Best to disable it if you remove the cat.

Incorrect Sir.

The vacuum from intake opens the valve under the tank and allows the exhaust gasses to be recycled into the air box.
THAT IS only if the valve is REAL - yes I have seen them FAKE not able to ever function.

Take it all off and if popular I could supply the blanking plugs or do as some ppl do just cover the hole etc or cut a gasket without a hole n leave it all as if it is connected.

[tarote9025]

Incorrect Sir.

The vacuum from intake opens the valve under the tank and allows the exhaust gasses to be recycled into the air box.
THAT IS only if the valve is REAL - yes I have seen them FAKE not able to ever function.

Take it all off and if popular I could supply the blanking plugs or do as some ppl do just cover the hole etc or cut a gasket without a hole n leave it all as if it is connected.

Whats the benefit of removing it?

[Megadan]

Incorrect Sir.

The vacuum from intake opens the valve under the tank and allows the exhaust gasses to be recycled into the air box.
THAT IS only if the valve is REAL - yes I have seen them FAKE not able to ever function.

Take it all off and if popular I could supply the blanking plugs or do as some ppl do just cover the hole etc or cut a gasket without a hole n leave it all as if it is connected.

Actually, you are incorrect sir. It is an air pump. Known as a pulse air injection pump (aka PAIR ). It uses a line from the intake between the carb and cylinder head to create the pulses needed to drive the pump. This draws fresh air from the air box via another line to the air box, to the pump and then pumps fresh air into the hot exhaust path to help burn off any unburned hydrocarbons and aid in the catalyst function.

If you need any other proof, the simple fact that all of the lines in the system are rubber should be a clue, especially the unit off of the head. If it was true EGR, they would have to be metal for the simple fact that they would melt/fail rather quickly with up to 1000 degree exhaust gasses passing through them.

Other proof that it is not EGR is the simple fact that it is a pump. True EGR doesn't need a pump to function, just a valve. The extremely hot exhaust gasses are also very high pressure, and don't need assistance in traveling through a pipe.

This is the same basic system found on almost every emissions compliant bike sold in the U.S. No bike comes with EGR, but they all have a PAIR system and a EVAP charcoal canister (aka, TT250) as part of 50 state compliance.

Further evidence of this is a TT250 with an exhaust installed on it makes lots of nice after fires (proper name for what people call backfires, which actually go through the intake). This is the same reason why other big name bikes with exhausts block off or delete the pair system when an aftermarket system is installed. The extra oxygen in the system causes unburned fuel to essentially ignite on its own within the exhaust.

[tarote9025]

Thanks megadan im used to working on cars so egr is what popped in my head i did have a scooter with a pair system on it is there any real benefit to removing it?

[Megadan]

Thanks megadan im used to working on cars so egr is what popped in my head i did have a scooter with a pair system on it is there any real benefit to removing it?

Performance wise there is no real benefit. It just stops lots of popping and flames from traveling all the way through the system (Why 2LZ stated it will save the muffler packing). Beyond that, it just cleans up and simplifies the bike and removes a little weight.

[pete]

ok.. what it is or what it is not....

but the short is if you remove the AIS and not the cat
the cat will clog up faster....


...

[NzBrakelathes]

Actually, you are incorrect sir. It is an air pump. Known as a pulse air injection pump (aka PAIR ). It uses a line from the intake between the carb and cylinder head to create the pulses needed to drive the pump. This draws fresh air from the air box via another line to the air box, to the pump and then pumps fresh air into the hot exhaust path to help burn off any unburned hydrocarbons and aid in the catalyst function.

If you need any other proof, the simple fact that all of the lines in the system are rubber should be a clue, especially the unit off of the head. If it was true EGR, they would have to be metal for the simple fact that they would melt/fail rather quickly with up to 1000 degree exhaust gasses passing through them.

Other proof that it is not EGR is the simple fact that it is a pump. True EGR doesn't need a pump to function, just a valve. The extremely hot exhaust gasses are also very high pressure, and don't need assistance in traveling through a pipe.

This is the same basic system found on almost every emissions compliant bike sold in the U.S. No bike comes with EGR, but they all have a PAIR system and a EVAP charcoal canister (aka, TT250) as part of 50 state compliance.

Further evidence of this is a TT250 with an exhaust installed on it makes lots of nice after fires (proper name for what people call backfires, which actually go through the intake). This is the same reason why other big name bikes with exhausts block off or delete the pair system when an aftermarket system is installed. The extra oxygen in the system causes unburned fuel to essentially ignite on its own within the exhaust.

Good night mate
You have that well deserved rest

[Megadan]

Good night mate
You have that well deserved rest


Prove me wrong or don't bother speaking.

Go show me an EGR system with rubber hoses running between the exhaust and intake. Or the fact that pretty much every EGR system on the planet runs the EGR directly from the exhaust port/manifold directly to the intake manifold and NOT the air box, which it would promptly melt. I don't know if you heard, but in case you missed the memo, exhaust gasses right out of the exhaust port are close to or beyond a thousand degrees Fahrenheit. Those kinds of temps make short work of most plastics and rubbers. There are exceptions, but they aren't found on these bikes.

You know what does run between the airbox and an exhaust port that also uses pulsation or port vacuum to drive along with rubber hoses that draw clean filtered air from an air box? A PAIR system.

Well, since you seem to think I am completely ignorant and only the big manufacturers know what they are talking about (how could I, a guy with years of training and experience, possibly know). Let's see what CSC calls it?
https://store.cscmotorcycles.com/TT250-OEM-AIR-PUMP-p/zt16-101.htm
Look, they call it an Air Pump. *shocked face* Not an EGR valve. That sting to your ego will go away, eventually. Also. don't forget that according to you these "big manufacturers" know more than little old me. Saying they are wrong now would disqualify every other attempt you have made to tell me I was wrong in your passive aggressive little way.


Anyway, I tire of you, but I want to leave you with a little pearl of wisdom for the next time you make a post about how you are so unfairly treated because you paid money to be a sponsor/vendor/etc.

Respect is earned.

[Megadan]

Apologies, Hancadam, for the above post in your thread. If you so desire you can have it deleted by an admin and I wouldn't mind. It just had to be said.

[Hancadam]

No apology needed, none of the discussion bothers me.

[2LZ]

Back to our regularly scheduled program...

Hancadam, since I have this freakish need to make brackets out of scrap, I ended up mounting it like this on Mrs. 2LZ TT250. I thought it turned out cool and I also fulfilled my bracket fetish. ;-)
My main concern was to have the muffler spaced out enough as to not cook the license plate plastic holder...which has been done here prior.

[DualSport]

Does wrapping up to the muffler help with preventing oxidation?

Also too bad nobody has a motorcycle dyno.. I wouldn't be surprised if it actually reduced HP or torque without very specific valve and jet setup..

[tarote9025]

Back to our regularly scheduled program...

Hancadam, since I have this freakish need to make brackets out of scrap, I ended up mounting it like this on Mrs. 2LZ TT250. I thought it turned out cool and I also fulfilled my bracket fetish. ;-)
My main concern was to have the muffler spaced out enough as to not cook the license plate plastic holder...which has been done here prior.

That is definanetly a more sophisticated solution then pounding it in to submission with a rubber mallet like i did lol. And for the record my rear fender melted in the best place for it to, the license plate covers it up. And for dual sports question it helps the exhaust gases travel through the muffler better i wrapped mine for the specific reason i dont want my pants to catch on fire or burn my calf while going down the road. Everytime it rains it will smoke for about 5 minutes until that moisture burns off. Every time i come from a wet ride off road or get caught in the rain i have people honking thinking my motor is about to blow up but they give me more room on the road so win win in my opinion

[Megadan]

From my own experience, once you sort out the jetting after adding an exhaust, the mid range and top end power do definitely improve. A majority of that is thanks to the lack of the catalyst in the head pipe, which is ridiculously restrictive.

Further proof would be in the gain of about 5mph with no other changes to the bike being made besides jetting. Mikuni clone properly jetted on a stock bike would do 62-63mph vs. 67-68 after the exhaust and re-jet. Same 17/45 sprockets as it had before, no other changes made.

Simply slapping on the exhaust otherwise wouldn't likely gain much of anything as the bike gets lean pretty quickly.

[Hancadam]

Here is how I hung mine
https://i.ibb.co/7GFfH90/IMG-20190419-122424375.jpg (https://ibb.co/ZhCj3Zb)

And plate clearance:
https://i.ibb.co/VBwyghK/IMG-20190419-125550439.jpg (https://ibb.co/rydPxLW)

[2LZ]

i wrapped mine for the specific reason i dont want my pants to catch on fire or burn my calf while going down the road.

Exactly why I wrapped Mrs. 2LZ bike. The last thing I wanted to hear was how she burned herself.

"Theoretically", wrap makes the exhaust gasses travel faster but with the huge displacement, fire-breathing, untamed horsepower of the mighty CG motor, I'm sure we're just a mod away from 11 second quarters. ;-)

[2LZ]

Also too bad nobody has a motorcycle dyno.. I wouldn't be surprised if it actually reduced HP or torque without very specific valve and jet setup..

One of our old members had a dyno. Here's his Qlink XF200 after some minor mods.

https://youtu.be/etRnYRIVs_M

Here's an old member who dyno'd his Roketa DB07a. (CG200 motor)

http://www.chinariders.net/showthread.php?t=813&highlight=dyno

[Megadan]

I will always wrap my exhaust at least from the rear slip joint to right before it makes the bend back to the head. Outside of the practical reason of no leg searing, it helps cut down on radiant heat to the carb and engine a bit as well.

[tarote9025]

Exactly why I wrapped Mrs. 2LZ bike. The last thing I wanted to hear was how she burned herself.

"Theoretically", wrap makes the exhaust gasses travel faster but with the huge displacement, fire-breathing, untamed horsepower of the mighty CG motor, I'm sure we're just a mod away from 11 second quarters. ;-)

Im thinking ill be getting down to 9 seconds on my bike in a week or so red adds 5 horse.

[Hancadam]

Here's a quick clip of how it sounds.

https://vimeo.com/331494432

PS: green adds 5.5hp

[mybike]

Here's a quick clip of how it sounds.

https://vimeo.com/331494432

PS: green adds 5.5hp

Always wondered how loud these ebay exhaust are. Sounds kinda loud in the video but how loud are they in person on the road and on the gas?

My exhaust on my Magician is real mellow at idle and not to bad at 3000-4000rpm, but boy when you get on the gas man is it loud. One of my Harley owner friend took my bike for a ride and when he got back his first words were " man this is loud" and we all know how most Harleys sound.

[Hancadam]

For me, it's right at almost too loud. But what makes me happy with it is how good it sounds. It sounds like a bigger engine.

[mybike]

For me, it's right at almost too loud. But what makes me happy with it is how good it sounds. It sounds like a bigger engine.

Thats just how I feel with my exhaust sound. Mine also sounds like a bigger engine. I would say maybe a mini Harley lol.

[2LZ]

For me, it's right at almost too loud. But what makes me happy with it is how good it sounds. It sounds like a bigger engine.

Yep....almost too loud but a great sound. I think I'm turning into my dad though. Exhaust sound never used to bug me.

[Azhule]

I will never get "old mans ears"... I'm sticking to my:

"Loud pipes saves lives" age :hehe:

Or at least they have saved my ace a number of times

A horn just doesn't cut it anymore... everyone on the road seems oblivious to them... but when a jerkhole taking over your lane hears you rev bomb them... they usually get the hint... if not that's when a "Hammer Blow to the mirrors" comes into play :p