03.v.x.x Home

03.v.2.2

What it fits...

2003/2004 Kawasaki Ninja ZX6R/RR.
2005/2006 Kawasaki Ninja ZX6R/RR. With modifications to the bike and a header swap.
2006 Kawasaki Ninja ZZR600. With a header swap.
It is possible to fit this exhaust to other Kawasaki motorcycles. It's designed to fit the stock (OEM) headers on the 2003 ZX6R. If those headers can be bolted to another bike, the exhaust should work. But, I make no guarantees to that.

How loud is it...

Idle (1-1.5k rpm): 75 dB
7k RPM: 104 dB
10k RPM: 120 dB
14k RPM: 125+dB (pegged my meter)
Sorry, I don't have the stock numbers to compare.

The story that started everything...

I'm sure I'm not the only one to have seen the "GP" exhausts on the track and on a few new bikes, and thought that looks sweet. So I went to the 'net and started searching to find one for my '03 ZX-6R. Nothing, but I kept searching. Still nothing.

Then, I turned to the new R6 for inspiration. Then after some brainstorming and 3D modeling I found a pretty basic idea and thought, HEY, I could really build this. So, then it was off to the garage to take my bike apart to see just what would fit. Then an even more simple design came to mind. Back to the 3D modeler I went. Once that was finished, the poster board and tape came out, just to make sure the dimesions were accurate. Damn I'm good, perfect fit. So, after some thought and many hours of searching to find sources for all the materials I would need, I started ordering enough to build one or two. Slowly UPS and DHL left me a few presents and I had everything I needed.

Now it's off to the garage to build a working prototype..........more to come later.....stay tuned

I turned to my dad for some help with the welding. Since neither of us had ever welded this kind of material before, we just set the welder close to what we thought and gave it a try. Oh were we way off. The first prototype welds look like a$$. But hey, that's what a first prototype was for. So, after some reading and talking to people that know more, we tried again. The second looks so much better. I feel comfortable going ahead with this. But, please remember I am not a professional welder, but I will do my best.

Working prototype......

Exhaust Revision Information:
Current Revision: 03.v.2.2

After the last batch I noticed a few things that could be changed to help make fabrication and assembly easier. So I've made a few changes to the design of the end rings. The welded nuts are still being used. The overall look of the outside has not changed. But it's enough of a change to make the 03.v.2.2 available. With the new end ring design, the 03.v.2.2 is available now.

After a getting the first batch done, and starting the second. I thought there has got to be a better way to get threads for all these holes. Threading (12) holes for each exhaust takes too much time. So after some thought, I decided to have the holes cut a bit larger and weld nuts to the back side of the rings. The takes less time and gives the bolts more threads to engage with. In turn, make a stronger connection. With welded nuts, the 03.v.2.1 is available now. The 03.v.2.1 has been discontinued in favor of the new end ring design.

After some thought and a few revisions.....Welded (the sealed 03.v.1.0), Bolts and threaded rings (the re-packable 03.v.2.0). I changed the design so it was bolted together. This will make it re-packable in the future. With threaded end rings, the 03.v.2.0 is available now. The 03.v.2.0 as been discontinued in favor of welded nuts.