Emmisions equipment removel w/pics. UPDATED w/ cat removal.

[Mountainwolf]

Hello Everybody,


I'm back with another project, again on a 07 Shineray Allroad 200cc. This time I will be removing all the emmisions stuff from this bike. There is no requirement for emmisions where I live so there is no need for this stuff on my scoot. Might wanna check in your area before doing this to yours.

Stuff to be removed;

http://i293.photobucket.com/albums/mm64/Mountainwolf69/emmisionsstuff.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view¤t=emmisionsstuff.jpg)

http://i293.photobucket.com/albums/mm64/Mountainwolf69/dontknow.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view¤t=dontknow.jpg)

http://i293.photobucket.com/albums/mm64/Mountainwolf69/ventintocarb.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view¤t=ventintocarb.jpg)


Stuff that needed to be pluged off included this one on the carb inlet manifold;

http://i293.photobucket.com/albums/mm64/Mountainwolf69/holeneedsplugged.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view¤t=holeneedsplugged.jpg)

and this one on the cylinder

http://i293.photobucket.com/albums/mm64/Mountainwolf69/dontknow.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view¤t=dontknow.jpg)

These were done like so,

http://i293.photobucket.com/albums/mm64/Mountainwolf69/makinplug.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view¤t=makinplug.jpg)

http://i293.photobucket.com/albums/mm64/Mountainwolf69/plugged.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view¤t=plugged.jpg)

Same routine with the one on the cylinder, used a small lag screw and some silicone as well, painted silver to match.

http://i293.photobucket.com/albums/mm64/Mountainwolf69/doohikyfixed.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view¤t=doohikyfixed.jpg)

http://i293.photobucket.com/albums/mm64/Mountainwolf69/pluged.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view¤t=pluged.jpg)

There was a hose going from the cranckcase to the emmisions doohiky, removed it and using one of the longer pieces with a nice prebent 90 degree routed it down and through the swingarm towards the ground;

http://i293.photobucket.com/albums/mm64/Mountainwolf69/CCVENT.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view¤t=CCVENT.jpg)


All the stuff I pulled off;

http://i293.photobucket.com/albums/mm64/Mountainwolf69/stuffremoved.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view¤t=stuffremoved.jpg)

Hope this helps anyone wanting to do this, saw no difference in idle and doubt it will effect anything.



OK Everybody,

After rereading this thread and seeing the mention of the lump and the possibility of a cat in the header pipe I just couldn't help myself. Here are some more pics and the results of my find.

The header pipe unmolested;

http://i293.photobucket.com/albums/mm64/Mountainwolf69/headerunmolested.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view&current=headerunmolested.jpg)

Holy crap Batman!!

http://i293.photobucket.com/albums/mm64/Mountainwolf69/holycrapbatman.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view&current=holycrapbatman.jpg)

It's coming out it just don't know it yet;

http://i293.photobucket.com/albums/mm64/Mountainwolf69/inplementofdestruction.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view&current=inplementofdestruction.jpg)

It wants to fight me but its gonna lose;

http://i293.photobucket.com/albums/mm64/Mountainwolf69/notgoingwell.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view&current=notgoingwell.jpg)

I WIN!!! HAHAHAHAHA

http://i293.photobucket.com/albums/mm64/Mountainwolf69/camelosefinally.jpg (http://s293.photobucket.com/albums/mm64/Mountainwolf69/?action=view&current=camelosefinally.jpg)


It took about five minutes with the drill press, going really slow, the stuff doesn't drill out it kinda compacts. It finally just caught and spun out. As soon as it stops SNOWING here I will install on bike #1 and see what the difference is if any. The cat make a hell of a restriction though so there might be a little gain. I won't bore you with all the welding pics, cheap ass thin steel is all I will say.

Wolf

[usmc-mustang]

Careful with silicone in or around fuel or fuel vapors. It will turn to a goeey mess, and get into the carb and intake. You might want to think about going to the Autoparts store and buy a .99 vacuum plug.

I doubt you will see any inprovement with it, minus the weight. This is a simple AIR injection system. When the throttle is closed, high vacuum over 20" will pull the AIR valve open, allowing fresh air into the exhaust.

You might notice popping out the exhaust now, as you will likely have high HC in the exhaust.

I am no enviro-hippie, just an ASE Master Tech who once apon a time did emission testing in CA.. I pulled the emissions crap off mine, but used a vacuum plug, and CNC'd a plate to cover the hole where the old tube was.

[Mountainwolf]

Careful with silicone in or around fuel or fuel vapors. It will turn to a goeey mess, and get into the carb and intake. You might want to think about going to the Autoparts store and buy a .99 vacuum plug.

I doubt you will see any inprovement with it, minus the weight. This is a simple AIR injection system. When the throttle is closed, high vacuum over 20" will pull the AIR valve open, allowing fresh air into the exhaust.

You might notice popping out the exhaust now, as you will likely have high HC in the exhaust.

I am no enviro-hippie, just an ASE Master Tech who once apon a time did emission testing in CA.. I pulled the emissions crap off mine, but used a vacuum plug, and CNC'd a plate to cover the hole where the old tube was.


USMC-mustang,

Thanks for the heads up on the silicon,, I just wanted a good seal and this is what I had laying around,. will try to find a vacuum plug tomorrow. As for the other side, I don't have access to a CNC machine and couldn't find a piece of steel that was the right thickness in the shop, found a piece at a friends though and gonna redo it right tomorrow.

You said,

" You might notice popping out the exhaust now, as you will likely have high HC in the exhaust."

What is the HC you are referring to??


Thanks again for the heads up,

Wolf

[usmc-mustang]

HC is hydrocarbons, or unburnt fuel. With unburnt fuel in the muffler, you are likely to get a backfire in the muffler. AKA a popping sound. This is more common in an engine that runs lean rather than rich, as it has a tendency to miss on cylinder firing. A muffler that is straight through and not baffled also has a less likelyhood of "popping".

You dont need a CNC machine, infact I dont have one, but I do have a friend with one. a piece of 1/8" x 3/4" plate steel will work perfect. Just it to the same length as the original valve, and use a bench or angle grinder to round the corners off. Drill holes, and you are done.

Dont try to weld the original unit. It is some funky chinese pot metal, and even with my TIG welder, it began to melt it. I tried it with my MAPP gas torch, and it finished it off to a goo of the finest chinese metal..

[Mountainwolf]

USMC-mustang,

I got ya on the HC question. Was gonna do that exact thing the piece of steel I picked up tonight. Wouldn't even think about welding this stuff the Chinese call "steel". Thanks all the input, great help on the project.

Wolf

[usmc-mustang]

Just noticed yours comes out the side. This must be some change between manufatures, as mine came out the top of thead next to the exhaust port.

Everything is the same, but it looks like yours is Steel rather than whatever mine was made of.

[Mountainwolf]

USMC-mustang,

It wasn't steel, took maybe 2 seconds to go through with my little cutoff tool. I think if I hit with a torch it would melt in seconds. As you put it soooo well, "it finished it off to a goo of the finest chinese metal" HAHAHAHA it makes me laugh every time.


Wolf

[TeamCheap]

Oh I'm so glad our bikes didnt have all that junk on them.
(nice pics)

I gotta ask :
What is that lump in the exhaust header pipe ??? :lol:
(dont tell me it's a catalitic convertor of some sort :lol:)

[fatboy250]

You may want to link this in the DS official prep thread for all the guys that want to do this when they are assembling. Just a thought.

Jason

[PorterzCustomz]

Oh I'm so glad our bikes didnt have all that junk on them.
(nice pics)

I gotta ask :
What is that lump in the exhaust header pipe ??? :lol:
(dont tell me it's a catalitic convertor of some sort :lol:)

Yea that sucks that it comes with all that garbage.

I don't think it's a cat, at least I hope its not. Maybe he welded it in for more flow, it is slightly bigger piece of pipe lol

I wounder what program he uses to get the cute little arrows :)

[usmc-mustang]

I gotta ask :
What is that lump in the exhaust header pipe ??? :lol:
(dont tell me it's a catalitic convertor of some sort :lol:)

For those who dont know, yes, that is a Cat. Also note, that you will need to replace the Headpipe and muffler to eliminate it. This is how i went about it in my Viva. As i recall, it isnt a regular style monocathylitic Converter, but rather a heavy platinum.

I did a little research into it, but it was a bass ackwards emissions set up. Shouldnt have been supprised when I say the AIR injection setup.

Know for us who have been to China, now understand why you cant see Bejing Airport when you come in for a landing.. Smog up to 20k ' elevation.

[TeamCheap]

Oh it's true then :lol: I feared thats what that lump was but didnt want to accept it but I have been seeing more and more of them on all sorts of motorized things.

[PorterzCustomz]

A CAT!!!????

I never thought id see a day when they used cats on dirtbikes. If I were him when he did his exhaust mods I would have gutted it.

[usmc-mustang]

A CAT!!!????

I never thought id see a day when they used cats on dirtbikes. If I were him when he did his exhaust mods I would have gutted it.

Good luck. Impossible would be putting it lightly. Unlike your typical "honeycomb" cat, this is platinum, and other heavy metals. You will bend whatever it is you try to beat it out with, no to mention a plugged exhaust. You are best off with replacing the headpipe and muffler with a non cat unit.

[AZ200cc]

Careful with silicone in or around fuel or fuel vapors. It will turn to a goeey mess, and get into the carb and intake. You might want to think about going to the Autoparts store and buy a .99 vacuum plug.

I doubt you will see any inprovement with it, minus the weight. This is a simple AIR injection system. When the throttle is closed, high vacuum over 20" will pull the AIR valve open, allowing fresh air into the exhaust.

You might notice popping out the exhaust now, as you will likely have high HC in the exhaust.

I am no enviro-hippie, just an ASE Master Tech who once apon a time did emission testing in CA.. I pulled the emissions crap off mine, but used a vacuum plug, and CNC'd a plate to cover the hole where the old tube was.


USMC-mustang,

Thanks for the heads up on the silicon,, I just wanted a good seal and this is what I had laying around,. will try to find a vacuum plug tomorrow. As for the other side, I don't have access to a CNC machine and couldn't find a piece of steel that was the right thickness in the shop, found a piece at a friends though and gonna redo it right tomorrow.

You said,

" You might notice popping out the exhaust now, as you will likely have high HC in the exhaust."

What is the HC you are referring to??


Thanks again for the heads up,

Wolf


Also blue silicone is for water applications like thermostat gaskets, Not reALLY meant for high heat applications.

[usmc-mustang]

Careful with silicone in or around fuel or fuel vapors. It will turn to a goeey mess, and get into the carb and intake. You might want to think about going to the Autoparts store and buy a .99 vacuum plug.

I doubt you will see any inprovement with it, minus the weight. This is a simple AIR injection system. When the throttle is closed, high vacuum over 20" will pull the AIR valve open, allowing fresh air into the exhaust.

You might notice popping out the exhaust now, as you will likely have high HC in the exhaust.

I am no enviro-hippie, just an ASE Master Tech who once apon a time did emission testing in CA.. I pulled the emissions crap off mine, but used a vacuum plug, and CNC'd a plate to cover the hole where the old tube was.


USMC-mustang,

Thanks for the heads up on the silicon,, I just wanted a good seal and this is what I had laying around,. will try to find a vacuum plug tomorrow. As for the other side, I don't have access to a CNC machine and couldn't find a piece of steel that was the right thickness in the shop, found a piece at a friends though and gonna redo it right tomorrow.

You said,

" You might notice popping out the exhaust now, as you will likely have high HC in the exhaust."

What is the HC you are referring to??


Thanks again for the heads up,

Wolf


Also blue silicone is for water applications like thermostat gaskets, Not reALLY meant for high heat applications.

Correct. 300' f to be exact. Now if you use 1B or 2B it would be fine for fuel usage, and have a heat rating to over 350' F. I doubt the motor would ever see temps over 250, and if you did, I would be concerned about oil temps.

[kens97sto171]

If you take the CAT off, take it to a recycler unless you want to keep it for spare parts... Platinum is selling for over $2000 an ounce... I have been hearing of people cutting CATS off pickups while they are parked in a shopping lot... CRAZY STUFF>..

Ken

[Cal25]

:idea:
I paid 950 for my bike. I wonder how many ounces of platinum is in the cat :?:

[Mountainwolf]

TTT bumping my own thread sorry.

[usmc-mustang]

TTT bumping my own thread sorry.


No problem. Told you that the stuff wasnt going to break out. Its some really hard stuff. Not your typical cat. No idea how well it worked, but it is enough to let the Viva VX200SX to get a CARB approval for road useage. I just junked the headpipe, and installed a new tailpipe and the old silencer of my Yammy RZV500R. You went the hard way. Geez a XR200 headpipe is 15-25 bucks on Ebay.

[Mountainwolf]

usmc-mustang,

I hate buying stuff off of Ebay, hate waiting for stuff to arrive. Besides this was a 30 minute project from start to finish. Actually came out easier than I thought it would after I saw what was in there. Well off to work. Pray for some sunshine, I'm tired of winter.

Wolf

[fatboy250]

Wolf,
Wow!! I had no idea what was in there. I will definitely be going this route to free up some hp.

[Cal25]

Wire welder to stitch it back up?

[katoranger]

Wire welder to stitch it back up?

The metal is so thin it is tough to weld it without burning holes.

Allen

[Cal25]

I have a friend that if I was to make a statement like " it can't be done" He will do to proove me wrong :roll:

[katoranger]

Difficult, but not impossible.

I welded the seams on my muffler back up, but it wasn't easy. My welder has like 5 settings for heat so it is either 1 or 2 no 1.5 selection available.

The speed has alittle more adjustability.

I am also not a pro welder.

I managed, but it is ugly.

Allen

[Mountainwolf]

Hello Everybody,

Yes I used a MIG to weld it back up, the trick I have found is to just tack it a little at a time, make a tack and move a 1/4 inch and make another tack, do that all the way around and let it cool for a bit and start over. The metal is so thin that it gets hot really quick, I have heard body shop guys talk about this but never experienced it myself because I don't weld thin stuff.

NOW lets talk about improvement of the power, WOW MAN!! GO BABY GO!! This was the exhaust mod to do. I did the back end of the pipe and noticed nothing, this made a REAL difference. Just like a straight pipe now. Backfires on the decel a bit but I don't care, sounds good, feels good and I like it!! Worth the 30 minutes to do this. Hope this helps everyone wanting to do this.

Wolf

dudes...it never ceases to amaze me how you guys weld stuff, etc. I wish to high heaven I'd have stayed in school and learned some welding or at least had a mentor to teach it to me. When I was younger this sort of thing didn't spark my interest but now as I am fast approaching 40, I find myself wanting to learn. But, since buying this bike, I have learned a lot. Like someone said before on here and I cannot remember who, you don't just buy a bike when you get a china bike, you get a motorcycle repair course. :D

[Cal25]

I bought a welder about 8 or 10 years ago. I'm still learning.

Learning is the No. 1 reason I have enjoyed this forum so much. Thanks to Frostbite for provideing it and the members for contributing.

The cat removal is now on the list. Thanks!

[usmc-mustang]

Difficult, but not impossible.

I welded the seams on my muffler back up, but it wasn't easy. My welder has like 5 settings for heat so it is either 1 or 2 no 1.5 selection available.

The speed has alittle more adjustability.

I am also not a pro welder.

I managed, but it is ugly.

Allen

The cat headpipe appeared to be thicker than the non-cat head pipe. Didnt actually cut and measure one but you can see it in the flange. Guessing it is to take the extra heat that the cat will generate.

I tossed off my cat head pipe and welded on the the new one to the extension pipe. Man I hope I never have to take it off.

[Funkmeister_Smith]

Hi.

Sorry to dredge this old post up, but its the only relevent post I could find in regards to my problem! :s

I have recently got my second Chinese bike (first one was stolen :? ), and its a 2007 Shineray XY200GYE. It too had the emissions rubbish that is explained in this post so I set about removing it. Its all came out a treat and I have blocked off all the (now un-necessary) outlets and inlets as described in this post. My problem is though that the pipe that comes out of the bottom end of the engine is kicking out alot of oil? In this guide it says you just led a long pipe down through the swingarm and pointing toward the ground, presumabley just as a breather pipe I assume, but mine is just spluttering out oil? I tried blocking it off completey by attaching a short length of pipe with a thick bolt siliconed in the other end but it just burst the pipe off and sprayed oil all over the rear shocker! :roll:

Could anyone confirm what function this pipe actually has and if its ok for me to block it off completely with silicone? Its the one in this picture:

http://i293.photobucket.com/albums/mm64/Mountainwolf69/CCVENT.jpg

Thanks in advance (hopefully! :wink: )

Steve

[Reveeen]

Could anyone confirm what function this pipe actually has and if its ok for me to block it off completely with silicone?

It is the crankcase breather tube, and no, it is not a "good" idea to block it off (otherwise the crankcase can't breathe, which it HAS to do, as the physical size of the crankcase changes as the piston goes up and down)

Some oil out of this tube is ok, but too much oil is caused by:
1) over filling
2) compression loss past the rings

Maybe running the hose as high as you can, then down, will slow the oil loss? There may be an internal baffle that is missing? (either plain missing, or not installed because the intention was to run it into the "box" and 10 cents could be saved)

[david3921]

It's supposed to go to the airbox to burn the oil 'smoke'.

[Funkmeister_Smith]

Hi.

Thanks for your speedy replies. :wink: Right then, I won't block it off! I'll try and route it high like you say then back down again, see if that helps. Theres not a 'massive' amount of oil coming from it, but enough to be a nuisance and make a small pool of oil when I park up. :s

Cheers again!

Steve

[Reveeen]

Once upon a time, far, far, away........ you would direct that "oil smoke" to whatever chain needed lubricating, be it the primary (with a dry clutch), or the drive chain. At that time, and place, a little oil "leaking" was just your bike "marking it's spot" (so it would know where "home" was if the driver was on holiday).

[david3921]

Once upon a time, far, far, away........ you would direct that "oil smoke" to whatever chain needed lubricating, be it the primary (with a dry clutch), or the drive chain. At that time, and place, a little oil "leaking" was just your bike "marking it's spot" (so it would know where "home" was if the driver was on holiday).

..good one :lol: