What happens when you
decide you need some more power out of your stock Banshee? Get some
pipes and re-jet the carbs. We decided to do a pictorial of
the installation process of the new Toomey Racing TR-6 pipes
and silencers. Where do you start? Take a Bone Stock 2003
Yamaha Banshee and $650 cash to purchase the top of the line
Toomey TR-6 pipe kit. With a good variety of hand tools and some
mechanical ability we can get started.
We
started by removing the radiator surround, tank plastic, seat,
rear plastics, and front plastics. We were sure to take care
in putting all the mounting bolts back into there place, as not
to lose them. Put all the body items aside
because you will not need them for a couple of hours. Next
we moved onto removing the stock exhaust system. We started by
loosening all the bolts and clamps. We removed the silencers
and stingers. Then we removed the springs from the pipes and
left the exhaust hangers in place, these will be used on the
new pipes.
Now the
Fun part, re-jetting the carburetors. There are two common
mistakes that are made when re-jetting the carbs. 1.Putting
the Left Float Bowl on the right carb. 2. Putting the slides
back in the wrong carbs. We were going to make sure that we
did not make these mistakes by working on one carb at a time.
We started this task by removing the air box and rear
boots from the carbs. We next removed the fuel lines and choke
line between the carbs. With the carb still in place we loosened
the carb caps. We removed the left carb from the carb cap and
T.O.R.S. system. Next remove the four screws from the float
bowl and take the float bowl off. This exposes the main jet.
Remove the plastic guard and loosen the jet with a 6mm nut
driver. Tip: Keep your finger in the carb to keep the Main
Nozzle from falling out. Replace the main jet with the
appropriate size for you altitude. In our case a 280 Main Jet.
We reassembled the carb bowl and moved onto replacing the
needle. With the throttle spring compressed with our fingers
we removed the throttle cable retaining screws from the slide
and pulled out the needle. We replaced the OEM needle with the
one supplied in our Jet Kit. We set the c-clip to the fourth
position as specified by our instructions. We reassembled the
carb completely and replaced it. We repeated the procedure for
the right carb and replaced it. We then made sure that the
carbs were perfectly synchronized. We replaced the air box
assembly and rear carb boots. On to the next step.
According
to the instructions we need to reverse the radiator hose so
that the Heat guard is located at the other end of the hose.
Using a clean pan to catch the coolant, we drained the coolant
and reversed the hose. We then refilled the radiator with the
proper mix of coolant.
We next
started the installation of the Pipes, Stingers, and
Silencers. First we attached the stingers to the silencers and
set them aside. We started with the left pipe turning the
handlebars to the left to give us more clearance from the
tie rod. We set the pipe in the frame and attached the front
pipe hanger loosely. Next we attached the Springs with a
pair of needle-nose pliers. We placed the pipe sealing
clamps on the stingers and fed them through the frame and
mated them up with the pipes. We loosely attached the
stinger pipe bracket to the frame. (Kudos to Toomey for
for making the TR-6 pipes attach at three points instead of
two like on the T-5s.) Last but not least we attached
the Silencer hanger. We them went through and tightened the
entire pipe assembly. We repeated these step for the right
pipe assembly.
We
moved on, after a short break (it was 103° outside), we
reinstalled all the plastics and drilled one-inch holes in
the air box for the Uni-Vents. We made sure to go over the
entire bike to make sure we did not miss anything and tighten
all nuts, bolts, and screws.
The
very last step in our Pipe upgrade was to replace the spark
plugs with new ones and perform a plug chop to make sure our
jetting is correct, and there you have it. Three hours and
$650 bucks and we have an way more powerful machine. We will
be writing a full review on the Toomey Racing TR-6 pipes in
our Product
Reviews section soon.
