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Old July 20th, 2017, 01:16 PM Thread Starter
 
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Cat removal, fuel controller?

My cat is getting very hot on my 2015 XP4. Much, much hotter than I'd like to see. Thinking about removing it by cutting a weld, gut, and weld back together.

I've searched quite a bit, but can't find a straight answer on if I will need a fuel controller after the delete. I'd like to add a turbo in a year or two, so it wouldn't bother me to buy a fuel controller now (obviously one that can handle boost). We tend to ride pretty hard in the dunes, so I'm concerned about running too lean and cooking the engine. I have a Boondocker Ripp Tied clutch, but otherwise pretty stock. Any thoughts are appreciated

Thanks
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Old July 20th, 2017, 01:25 PM
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Re: Cat removal, fuel controller?

sub'd

Only in Canada... Eh !
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Old July 20th, 2017, 01:56 PM
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Re: Cat removal, fuel controller?

I have cut several stock mufflers and removed some have had controller and some without, it didnt seem to harm them without a controller and they run glamis pretty hard also. i even have a couple mufflers already done that the guys removed for a full exhaust

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Old July 21st, 2017, 08:08 AM Thread Starter
 
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Re: Cat removal, fuel controller?

familywagon, thanks! That's the type of response I'm looking for. I think I'll do some cutting this weekend...
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Old July 21st, 2017, 08:15 AM
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Re: Cat removal, fuel controller?

I gutted my cat and O2 still connected.
I don't have any scientific proof but it seems to run cooler and even takes awhile to heat up to operating temp even in 100*+ temps.
10 miles of riding and idling for a few minutes the fan finally came on.
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Old July 29th, 2017, 07:53 AM
 
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Re: Cat removal, fuel controller?

I did mine. No issues. I did just add a tune. No time on it yet. Tonight will be first good ride with tune.

2016 XP 4 1000
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Old September 7th, 2017, 06:49 AM Thread Starter
 
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Re: Cat removal, fuel controller?

So as a follow up, I did cut out my cat and welded it back together. The muffler case had noticeable hot spots on it, and I have no doubt that a couple more aggressive rides at the dunes would have burnt through the muffler. It's slightly louder, but not enough that I could even tell if someone else's cat was cut or not. I've given it a few runs around my property with good results, no dunes trips planned until October. I'll try and report back then.

Overall, I'd strongly recommend it.
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Old September 7th, 2017, 10:26 AM
 
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Old September 7th, 2017, 11:32 AM
 
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Re: Cat removal, fuel controller?

If you're worried about you might think about adding a fuel/air meter to be sure. If you do add the turbo down the road it will be good for that too.
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Old September 7th, 2017, 05:22 PM
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Re: Cat removal, fuel controller?

My follow up after gutting my cat is over 200 miles and no problems
No codes
No noticeable difference in decibels.
Has a better sound to it
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Old September 7th, 2017, 09:59 PM
 
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Re: Cat removal, fuel controller?

Did you guys take any pics of the muffler cutting?
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Old September 8th, 2017, 05:26 AM
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Re: Cat removal, fuel controller?

Quote:
Originally Posted by 44newman View Post
Did you guys take any pics of the muffler cutting?
If you're good with a grinder you shouldn't have to cut anything.
The elbow is inserted into the muffler and comes right out when weld is removed.
You can see @.56 where you need to grind the weld and remove the elbow.
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Old September 8th, 2017, 05:57 AM
 
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Re: Cat removal, fuel controller?

Very nice 185EZ, we all appreciate this
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Old September 8th, 2017, 06:39 AM Thread Starter
 
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Re: Cat removal, fuel controller?

Mine had two layers of pipe at the cat. I assume when they make the mufflers the cat is in it's own piece of tubing. I assume they slip it into the muffler then position the elbow over it, then the big ugly weld goes over all of it. I was able to cut thru a single, outside layer of the pipe right at the weld with a cutoff wheel on a grinder. This left me an easy way to reattach the pipe. Don't worry about trying to make it look nice

The cat was a total pain to remove. I figured a hole saw was the way to go, it wasn't. I ended up splitting the muffler lengthwise for a few inches and chiseling out the cat. Just welded the seam back up when rewelding the elbow back on.

Also, not sure if it's a problem or not, but I'd rec'd anyone welding it back together to disconnect their battery. Don't want to damage any electronics
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Old September 8th, 2017, 07:34 AM
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Re: Cat removal, fuel controller?

Jeddy, you did it all without removing the muffler?
The cat is tough as nails and I recommend drilling as many holes as possible for smaller pieces.
I had one piece a bit too large and had a hard time getting it out.
Once you get around to the outside of the cat it comes out pretty easy.
I had a lot of tiny pieces and wanted to make sure everything was cleaned out so I did a lot of shaking and blowing out with compressed air.
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