XT500Exhaust System
Restoring ideals with technology
The concept of our product is simple;
We want to reproduce the original exhaust system
of the 1976 XT500 (1N5/1E6) using modern materials and technology.
The early exhaust system is key to the identity of the XT500, and was created from a
draft image of the initial plans, followed by a full-size clay model prototype.
However, the quality of the steel used
for the original was poor, with many users facing
issues by rust and
corrosion over time. We build on the original concept to create a high
quality exhaust system that is lighter in weight, optimized geometry, and new metals.
Product Details
This product has been designed with a striking overall image without compromising on the design of the original.
The internal shape of the exhaust system is a faithful reproduction of the original. Using modern design technology, we were able to improve the efficiency and reduce the noise of the system.
The new exhaust system, reconstructed with stainless steel (SUS436L) is lightweight and corrosion-resistant, making it less prone to rust.
Through optimization with modern technology, the exhaust system now possesses a more refined shape — one that would have been impossible to create with the production technology of the past.
In addition to reproducing the original structure, the shape of the exhaust gas channel has also been redesigned thoroughly, creating a smoother torque curve while preserving the normal air intake settings.
Unfortunately, the original exhaust system's design was inefficient in terms of its cost, materials, and production-related limitations.
We utilized high-precision 3D-CAD structural simulations to calculate the strengths and stresses for each part to eliminate all deficiencies in the strength and rigidity.
The original exhaust system sacrificed a lightweight design to create a complex pipe layout, whose shape was finally achieved by integrating multiple auxiliary parts.
Reconstructing the exhaust system with modern technology has allowed us to create a high-quality product that is both robust and lightweight while still achieving its complex pipe layout.
Features
01Respect
Produced between 1976 and 1988, the XT500 still garners strong support from core fans.
A motorcycle packed with distinctive features, the model has an original design that crystallizes its development concept.
We undertake product development with respect for the orderly design of the XT500's early exhaust system, a design imbued with a powerful will born of the trial and error of its developers.
02High quality
The greatest weakness of the system is the low corrosion resistance and susceptibility to rust of the materials used in the original. To address this, we use high-quality stainless steel (SUS436L) compliant with Japanese Industrial Standards (JIS) to enhance corrosion resistance and create a product less prone to rust. Craftsmen skilled in metalworking in Japan carefully manufacture the systems, one by one, taking care in every detail, delivering the systems to users under thorough quality control.
03Weight saving
The original exhaust system has a weight of nearly 10 kg. This impairs the concentration of mass, considerably lessening the agility of the lightweight vehicle body. In response, we used lightweight, high-rigidity stainless steel and optimize the shape of every part without impairment of the original design, ensuring strength equal to or higher than that of the original.
04Bolt on
If your motorcycle is an early model (1N5/1E6), no special working is needed. The system can be removed from the package and installed
as-is.
Creation of design data through capture of the original exhaust system with a high-precision 3D scanner enables accurate reproduction of original shapes and allows installation on your motorcycle with no change from the original,
in every aspect from vehicle clearance and muffler protector mounting position to bolt sizes.
05Exhaust efficiency
We not only reproduce the original structure but also optimize the exhaust air stream form
in detail to yield a smoother torque curve while maintaining the intake settings of the original.
Based on power check using a chassis dynamometer, we produced multiple prototypes. Through repeated tests envisioning all manner of driving scenarios, we created an easy-to-handle model focused on the medium and low speeds typical of trail models, without loss of the characteristics of the original.
06Faithfully reproduce the original.
Through the use of a high-precision 3D scanner, we create detailed design data for external and internal shapes alike, then add redesigning to eliminate negatives in structure and strength. The result is a discerning design, created through modern manufacturing technology, that inherits the identity of the XT500.