Just might want to cover those welds in some hammerite when you get the chance to stop them from rusting. Apart from that good on yea and well done for taking it to yamaha a cutting out that stupid cat:SpinHappy_15XK8L:

Thanks for putting the "in progress" pics up Tim, interesting to see.

Stainless welds on a stainless box...

so can anyone tell me the disadvantage that may occur from this exhaust cutting exercise once using unleaded petrol again when bike back home.
seems a good idea otherwise.........

Nice work Tim.

Block off your AIS now to stop the popping.

I take it that with the cat removed the exhaust will be running a lot cooler than before ... is that the case?

I understand that should be the case but it's been about 30c in the shade here (much more in the sun) and the heat from the exhaust is far more noticeable on the Tenere than on any other bike I've recently owned.

Kev: what's an AIS?

AIS = Air Intake Sensor.

It's the link between the exhaust side of the engine and air box and opens up to burn off unburnt fuel with a closed throttle - or something like that.. It's what causes the bike to pop on the overrun or bang if you have an open single pipe like I do and scare the local wildlife.

If you either block the pipe at the air box end or as I did, remove the pipe completely and cap the air box and engine end with some plastic plugs and silicone adhesive (high temp').

The valve works and is both activated and monitored by the ecu, so you need to keep it connected.

Much better without the pipe..

http://www.xt660.com/showthread.php?...d=1#post101266

air induction system, if you take off the left hand side air box cover there will be a small hole which connect to a tube on the outside try and find a small rubber grommet to block the hole. When you shut the throttle off it let in clean air into the exhaust system to keep the emission reading low and does not effect the performance of the bike at all.

Well done by the way :respeck:

Nice work that man!!! Interesting modification indeed, as said earlier, it will be interesting to see what happens when using UK unleaded fuel once you are back in blighty, but I don't see any forseeable trouble, as the fuel is spent anyway by the time the gas reaches the cat. It would be worthwhile doing a plug chop and have a look at the mixture though, just to see if its not running too lean just a s a precaution. As Kev said, blocking the AIS at the exhaust or airbox end is a simple and effective little mod too. Please post more of your findings as you find out how it goes, as I'm mad keen to do the same to my bike.
Now, pass me that grinder............