Since '02 xBhp is different things to different people. From a close knit national community of bikers to India's only motorcycling lifestyle magazine and a place to make like-minded biker friends. Join us

#xBhpAxorHelmet #2

Axor
Castrol Power 1

Tubeless tyres are better than tubed ones.

Our Partners

User Tag List

Results 1 to 9 of 9
Like Tree9Likes
  • 3 Post By Manoj Sivaraman
  • 1 Post By xBhp
  • 1 Post By Zapps
  • 2 Post By Manoj Sivaraman
  • 1 Post By Manoj Sivaraman
  • 1 Post By Manoj Sivaraman

Thread: NS200 AS200 Catalytic converter removal (Decat, Cat delete)

  1. #1
    Addicted Manoj Sivaraman's Avatar
    Join Date
    Dec 2016
    Location
    Chennai
    Posts
    104
    Mentioned
    3 Post(s)
    Tagged
    0 Thread(s)

    Default NS200 AS200 Catalytic converter removal (Decat, Cat delete)

    Hi everyone,

    Hope things are going good in the lockdown. I had weekends to spend quality time in my motorcycle making some minor modifications.
    I feel that always catcons are pretty restrictive in nature although newer BS4 bikes use bigger and bulky ones built inside the muffler assembly. Which caused their price to be much higher than BS3 versions.

    Notable weight from BS3 to BS4 about 3 kgs heavier in muffler.
    So have disassembled the bend pipe and have sliced the catcon with angle grinder.

    Name:  IMG_20200524_160945.jpg
Views: 138
Size:  20.6 KB

    Catalytic converter weights around 0.5kgs

    Name:  IMG_20200524_160939.jpg
Views: 130
Size:  20.0 KB

    Corrugated roll type Catcon

    Have used 1.7 inch diameter pipe 18 gauge 304SS to replace the Catcon measured and cut replicating similar length.

    Name:  IMG-20200524-WA0049.jpg
Views: 131
Size:  20.0 KB

    Welded one side onto the bend pipe installed back on the bike marked and aligned Tac welded in place before running full weld.

    Name:  IMG_20200524_175944.jpg
Views: 125
Size:  20.9 KB

    Ignore poor finishing on welding since it's been quite a while on welding.

    Finished the bend pipe with wire brush wheel and some minor sanding with flap wheel.

    To add did powder coat with some high temperature powder coating which hardly costed me 150 bucks.

    Name:  IMG_20200601_195333.jpg
Views: 132
Size:  18.6 KB

    Name:  IMG_20200601_195340.jpg
Views: 130
Size:  16.7 KB

    Name:  IMG_20200601_195345.jpg
Views: 128
Size:  16.8 KB

    Name:  IMG_20200601_195357.jpg
Views: 132
Size:  16.3 KB

    Also to note post this have checked pollution with a local certifier. It passed with flying colors.

    So no problem with law breaking or so.

    I guess this write-up will be helpful, do discuss and comment on the workmanship.

    Thanks and regards.
    Manoj Sivaraman..
    Last edited by xBhp; 06-03-2020 at 05:26 PM.
    ashwanth.r, kiran2508 and guptavis like this.

  2. #2
    Moderator
    Join Date
    Dec 2015
    Location
    India
    Posts
    2,059
    Mentioned
    53 Post(s)
    Tagged
    1 Thread(s)

    Default Re: NS200 AS200 Catalytic converter removal (Decat, Cat delete)

    Thread approved.
    Manoj Sivaraman likes this.

  3. #3
    Rusted Zapps's Avatar
    Join Date
    Apr 2018
    Location
    Ludhiana, Punjab
    Posts
    1,058
    Mentioned
    10 Post(s)
    Tagged
    1 Thread(s)

    Default Re: NS200 AS200 Catalytic converter removal (Decat, Cat delete)

    Weird to know that this passed the air pollution test. More interestingly, does it pass the sound pollution test?
    Manoj Sivaraman likes this.

  4. #4
    Addicted Manoj Sivaraman's Avatar
    Join Date
    Dec 2016
    Location
    Chennai
    Posts
    104
    Mentioned
    3 Post(s)
    Tagged
    0 Thread(s)

    Default Re: NS200 AS200 Catalytic converter removal (Decat, Cat delete)

    Quote Originally Posted by Zapps View Post
    Weird to know that this passed the air pollution test. More interestingly, does it pass the sound pollution test?
    Audibly the note gets slightly throaty. No much change still bike is very quiet like normal NS200.
    Difference will be like the note on RTR160 and RTR 180. (Just for a comparo)

  5. #5
    Addicted
    Join Date
    Mar 2015
    Location
    chandigarh / solan
    Posts
    81
    Mentioned
    1 Post(s)
    Tagged
    0 Thread(s)

    Default Re: NS200 AS200 Catalytic converter removal (Decat, Cat delete)

    Quote Originally Posted by Manoj Sivaraman View Post
    So have disassembled the bend pipe and have sliced the catcon with angle grinder.

    Why did you do this? For the weight reduction?


    Ignore poor finishing on welding since it's been quite a while on welding.

    Finished the bend pipe with wire brush wheel and some minor sanding with flap wheel.

    You did this yourself? The welding and sanding?


    To add did powder coat with some high temperature powder coating which hardly costed me 150 bucks.

    The muffler looks really good. The exhaust pipe in my AS200 has started to develop a little rust. I would want to do this too.
    Please share the materials you used and describe the procedure a little bit. Can you post a picture of the powder coat? Was it a spray can? Did you apply a coat of paint over the powder coat?


    Also to note post this have checked pollution with a local certifier. It passed with flying colors.

    Why would Bajaj include this if it was not required to pass pollution test?

    Questions in bold.
    What is the part that remains on one side of the pipe? Is it the muffler? How was it connected to the catcon which you removed? I mean just a metal strip or was there a tube through which air would go from that part to the catcon?
    Last edited by guptavis; 4 Weeks Ago at 06:18 PM.

  6. #6
    Addicted Manoj Sivaraman's Avatar
    Join Date
    Dec 2016
    Location
    Chennai
    Posts
    104
    Mentioned
    3 Post(s)
    Tagged
    0 Thread(s)

    Default Re: NS200 AS200 Catalytic converter removal (Decat, Cat delete)

    Quote Originally Posted by guptavis View Post
    Questions in bold.
    What is the part that remains on one side of the pipe? Is it the muffler? How was it connected to the catcon which you removed? I mean just a metal strip or was there a tube through which air would go from that part to the catcon?
    Why did you do this? For the weight reduction?
    Not exactly, but it's one of the reasons.
    Catcon is a major restriction, causes turbulent flow in exhaust.
    We need flow to be less turbulent.

    You did this yourself? The welding and sanding?
    Yes, did all the welding and sanding myself. I have the all the required tools at home.

    Please share the materials you used and describe the procedure a little bit. Can you post a picture of the powder coat? Was it a spray can? Did you apply a coat of paint over the powder coat?
    Powder coating cannot be done at home. It is a powder based coating done by cathodic deposition. Curing is based on thermosetting procedure. You have high temperature as well as low temperature powder coatings. Ensure you do the high temperature one.
    Else you can cand it down and go for Hitemp aerosol can paints. They do last upto a year or so. ie.rustoleum, etc.

    Why would Bajaj include this if it was not required to pass pollution test?

    Bajaj cannot push out a vehicle without catcon unless it carries closed loop fuel injection system, only applicable for BS3 bikes.
    The pollution test we do on local test centres are not the exact standards. For example these ppl are not updated to newer standards. There is difference between the test procedure at ARAI, were every bike post design and development goes through rigorous testing. This mod is completely safe on engine as you are reducing the backpressure by a good margin.

    The boxy part under the engine at the bend pipe is the exhaust resonator. It aids in creating a negative pressure (vaccum) at lower speeds causing scavenging effect. This is what bajaj proudly calls as exhausTEC.

    I guess answer are informative.

    Thanks and regards
    Manoj Sivaraman..
    ashwanth.r and guptavis like this.

  7. #7
    Addicted
    Join Date
    Mar 2015
    Location
    chandigarh / solan
    Posts
    81
    Mentioned
    1 Post(s)
    Tagged
    0 Thread(s)

    Default Re: NS200 AS200 Catalytic converter removal (Decat, Cat delete)

    Quote Originally Posted by Manoj Sivaraman View Post
    I guess answer are informative.
    They are very informative. Thank you for explaining Manoj.

    Yes, did all the welding and sanding myself. I have the all the required tools at home.
    Great! Are you an engineer by qualification? You really did stay true to your studies then. I've never seen a welding machine since welding workshop in 1st year.

    Else you can sand it down and go for Hitemp aerosol can paints. They do last upto a year or so. ie.rustoleum, etc.
    Thanks. I have been thinking of using the Hi-Temp spray can. Just got dissuaded by some posts that said if you leave some rust/moisture before the paint, it can actually get trapped under the paint and make it worse!

  8. #8
    Addicted Manoj Sivaraman's Avatar
    Join Date
    Dec 2016
    Location
    Chennai
    Posts
    104
    Mentioned
    3 Post(s)
    Tagged
    0 Thread(s)

    Default Re: NS200 AS200 Catalytic converter removal (Decat, Cat delete)

    Quote Originally Posted by guptavis View Post
    They are very informative. Thank you for explaining Manoj.

    Yes, did all the welding and sanding myself. I have the all the required tools at home.
    Great! Are you an engineer by qualification? You really did stay true to your studies then. I've never seen a welding machine since welding workshop in 1st year.

    Else you can sand it down and go for Hitemp aerosol can paints. They do last upto a year or so. ie.rustoleum, etc.
    Thanks. I have been thinking of using the Hi-Temp spray can. Just got dissuaded by some posts that said if you leave some rust/moisture before the paint, it can actually get trapped under the paint and make it worse!
    Hi, Gupta

    Yes, I'm a mechanical engineer. Now pursuing my masters after 2 yrs of automotive experience. But trust me no college will teach these. Sometime we need to get our hands dirty. I love to work practically rather than go theory all the way.

    If possible get it sand blasted before painting with high temp paints.

    Thanks and regards
    Manoj Sivaraman..
    guptavis likes this.

  9. #9
    Addicted Manoj Sivaraman's Avatar
    Join Date
    Dec 2016
    Location
    Chennai
    Posts
    104
    Mentioned
    3 Post(s)
    Tagged
    0 Thread(s)

    Default Re: NS200 AS200 Catalytic converter removal (Decat, Cat delete)

    A small update to this thread..

    Post the cat delete the bike performance is definitely improved and bike tops around 151Kmph.
    BS4 NS200 exhaust is way throaty and grunty. I'm a fan of it since I drove one. Wanted my AS200 to sound similar. So quest started on how the internals differ from each other. Found out a bunch of informations.

    The catcon on the bend pipe is now moved to the underbelly unit.
    (So if anyone is willing to do a catdelete, now it's easy to just plonk in the BS4 bend pipe. It's a direct fit costing 1800ish. Advantage: you don't need to do the surgery I did. And you get a free flow bend pipe with OE finish).

    The BS4 muffler now houses a bigger catcon like it's KTM cousins. This is mainly done to increase the temperature at catcon by effectively insulating the entire catcon inside the muffler. Rather having them exposed under to incoming air flow which reduces the catcon temperature.

    The new BS4 weighs around 1.5kgs more than BS3.
    BS3 at 3.5kgs and BS4 at 4.8kgs.
    I need the lowest weight and the best sound. So bought a used BS3 exhaust and went with a small surgery..

    From here let the pictures speakName:  IMG_20201025_152140_20201026113537154.jpg
Views: 37
Size:  20.6 KBName:  IMG_20201025_165609.jpg
Views: 36
Size:  19.5 KBName:  IMG_20201025_152145.jpg
Views: 37
Size:  19.0 KB

    Thanks and regards
    Manoj Sivaraman..
    guptavis likes this.

Similar Threads

  1. Damaged catalytic converter
    By Themotoguy in forum Do it Yourself!
    Replies: 2
    Last Post: 05-30-2020, 10:04 PM
  2. Can i use AS200 fork assembly in NS200
    By SoNu46 in forum Help Me!
    Replies: 1
    Last Post: 05-09-2019, 04:40 PM
  3. Yamaha YZF R15 - Catalytic Converter (CatCon) Removal
    By HarishK in forum Do it Yourself!
    Replies: 20
    Last Post: 08-13-2013, 11:04 PM
  4. Platinum in catalytic converter
    By rx100.7050 in forum General Biking Discussion
    Replies: 4
    Last Post: 08-25-2012, 07:47 AM
  5. Need Catalytic Converter
    By RXZ5speed in forum Thumpers,2-Stroke And Exotics
    Replies: 2
    Last Post: 06-13-2011, 06:02 PM

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •