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UFO Cat Sass andAfterburner Exhaust System.
Preliminary Tuning and Dyno Testing results.
After numerous hours of studying and testing this new exhaust system and Max Tuner module, I have some results I am comfortable with posting. I am quite taken with the symmetric look and sound of the system. This system will be receiving extensive use, data logging and tuning from me in the near future. I should start with an overview of the system. As you may be able to see in the photo above, this system utilizes the stock front and rear header pipes. The Cat Sass is a direct replacement for the stock catalytic converter and has a growing selection of exhaust canisters (mufflers) that can be installed. The stock exhaust canisters (mufflers) can not be reused with this system. The current system supplied by UFO included exhaust canisters known as Afterburners. The Afterburners are of carbon fiber construction and have a packed primary baffle. They also include a steel secondary baffle that can be removed via a single bolt. This secondary baffle reduces the exhaust volume level considerably. The comparison video of the secondary baffles in and out can be seen here. This system also includes a adjustable fuel injection system tuner known as the Max Tuner. The injection tuner adjust the injector duty cycle timing to correct the air- fuel ratio now required by the exhaust system and/or intake air system change. Installation of this system by the average "back yard" mechanic can be performed with the bike on the kick stand. I am not going to go into set by step instructions, but rather highlight what I found to make this a little easier. I had the following special tools from Sears handy to perform this installation: Metric Tee Handle Ball End Allen Wrenches Metric Mid length Ball End Allen Bit Sockets Metric Short Length Ball End Allen Bit Sockets The mid length 8mm Allen socket on a long extension (the one above requires a 1/4" extension) will be required to loosen the clamps securing the rear header pipe to the catalytic converter. The Tee handle wrenches make loosening of the front flange nuts easier. It can slide between the main and sub radiator. Loosen the top nut first. This seems to relieve the tension on the exhaust flange. This makes it easier to loosen the bottom, harder to reach, exhaust flange nut.
Short Ball End Allen sockets on a Stanley Twist handle 3/8" drive ratchet with from Wal-Mart makes life easier for removing the top Allen flange nuts from the rear pipes. This ratchet is one of my favorites.
A regular Allen Wrench can be used to loosen the remaining exhaust flange nut.
If you do remove the exhaust pipe, for some reason, make sure you re-install the exhaust gaskets.
Installing the system. Start with the side that does not have the O2 sensor bung first. Install it on the front pipe and then rotate it onto the rear pipe. Secure the front clamp. Install the O2 sensor on the second pipe and follow the same procedure. Loosely install the exhaust cans and clamps. Here is an easy way for me to align the slash cut of the exhaust cans. I used a caliper to find the high point directly opposing the hole in the very bottom of the canister.
Using the two points found above, I installed tape for a visual indicator of the can's alignment. I then adjusted them to match. Secure all clamps.
The seat and tank top will need to be removed to install the Max Tuner. A video of how to do so can be found here. I would suggest installing the Max Tuner under the seat for easy access to future adjustment. I am not sure if a performance air filter will be a part of this kit, but I would suggest installing one and performing the air box modification as part of this upgrade. The stock filter, in any fashion, is just too restrictive. You have got the bike this far apart, might as well give your self a few more cheap ponies. You will be disconnecting the EXUP valve cables. I suggest removing the rear fender and removing the cables from EXUP servo. Also, remember to remove the O2 sensor before you drop the catalytic converter or you may tear the electrical connections out when the converter drops down. A conservative estimate of installation time would be three to four hours. If you plan to perform the air box mod in concert with this exhaust system upgrade, plan on a day of fun. Be very careful not to damage your radiator and paint. Once again, I suggest just loosening the nuts on the header pipe flanges rather than removing them. This keeps the pipes in place but allows enough play to install the new pipes. Also, loosen the front cross pipe bolt but leave it together. It you need the additional play, it will be there with this bolt loose. You may also want to use masking tape to protect areas where tools and parts may make incidental contact with the paint and/or plastic.
The NumbersAlthough I have extensively tested this system on my bike, I wanted to give a real world look at what to expect from installing this system on your bike. This testing was performed on Esten Spear's bike as we prepared it for Bike Week. We must first establish a baseline. Here is the "all stock" run that I performed prior to the installation compared to the Cat Sass with Max Tuner with a stock intake system. I would like to note, the Max Tuner is really set up to run with a performance air filter so the bike was a little rich in this test:
Here is the comparison of the stock bike verses the UFO Cat Sass, Max Tuner, foam rubber removed from the air scoops, Air Box Modification and Performance Air Filter. This is what I consider to be a "streetable" setup:
5/26/09 Update. The tune file has been reworked. The bike has pulled a 184 rwhp with better low end performance. See the Air Filter Challenge
Here is a comparison of the stock bike verses all of the above with the air box top removed. We installed the Race ECU for this test. The stock ECU bypassed makes the same numbers.
This is a proprietary "Drag Race" setup supplied by Jon Cornell of UFO. If you wish to pursue this information, please contact UFO for further info. This dyno chart image displays the potential that your internally stock, non-NO2, V-Max can have utilizing the UFO Cat Sass system. Although I do not consider this next chart to be a realistically street-able setup, here is the highest uncorrected horsepower I have made with this exhaust system:
I currently have the UFO Performance Cat Sass system installed on my bike and I will be testing and tuning the Max Tuner program. There will more to follow with this system. I have already adjusted the Max Tuner to correct for a possible harmonic caused by air box modification. It is a little better at 2.5 to 3k rpm. My last test was of a new N2O option available for the Max Tuner in which I made an SAE corrected 207.5rwhp with this system. The Max Tuner will apply the additional fuel required for a dry N2O shot. If you have any questions, e-mail me here. Related Pages: The video promo and Bang for the Buck
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