ZR8000 MUFFLER TEST PHASE 2

SLP (ceramic coated), MBRP (stainless), BMP PL, BMP trail, SPEEDWERX The Kaczor bothers Darren and Jim came back to test the rest of the aftermarket mufflers—this time using Jim’s brand new 2014 ZR8000 for our test mule. Our plan was to test all the mufflers with the engine bone stock then install the D&D Riot kit on the engine. Today, like we did during the first session, Darren monitored my laptop with the Arctic Cat diagnostic software to observe coolant temp and signs of detonation and resulting timing retard. We would monitor sound levels with a digital sound level meter sitting on the dyno control console next to the shatterproof window between the control room and engine room. This would give us an A to B comparison of the aftermarket mufflers compared to the stock muffler. After fitting Jim’s new sled with all of the dyno instrumentation we fired it up and did the first test with the hood/ pod in place. Then we removed the hood/ pod and installed the dyno pipe pressure/ temp fitting in place of the factory temperature probe. Disconnecting the factory probe from the wiring harness causes the ECU to default to 1030f where maximum timing is delivered. We duct taped the dyno airflow meter into the rectangular opening in the front of the airbox. The HP was the same as with the hood/ pod in place. STOCK MUFFLER, 20 lb 6 oz,, 4000 70 dB, WOT 82 dB EngSpd STPPwr STPTrq BSFA_B FulA_B AFRA_B Air_1s ExhPrs Exh_2 RPM CHp Clb-ft lb/hph lbs/hr Ratio SCFM psig deg F

6700 119.1 93.4 0.606 69.9 13.24 202.2 1.4 9646800 120.3 92.9 0.612 71.3 13.32 207.4 1.8 9766900 121.6 92.6 0.617 72.6 13.42 212.8 1.9 9827000 123.2 92.4 0.626 74.6 13.37 218.0 2.0 9877100 125.0 92.5 0.642 77.6 13.19 223.6 2.1 9907200 127.3 92.8 0.652 80.2 13.03 228.2 2.2 9927300 131.4 94.5 0.670 85.2 12.71 236.6 2.4 10007400 137.8 97.8 0.673 89.7 12.42 243.4 2.4 10117500 143.1 100.2 0.671 92.9 12.23 248.0 2.2 10207600 146.9 101.5 0.668 94.9 12.13 251.5 2.2 10297700 150.1 102.4 0.666 96.8 12.06 254.8 2.5 10397800 152.8 102.9 0.664 98.2 12.02 257.8 2.6 10507900 154.7 102.8 0.659 98.7 12.07 260.1 2.6 10598000 155.1 101.8 0.657 98.6 12.18 262.3 2.5 10678100 153.2 99.3 0.664 98.3 12.30 264.1 2.6 10698200 145.0 92.9 0.699 97.9 12.36 264.4 2.5 10618300 127.7 80.8 0.754 93.0 11.90 241.7 2.2 1039

SPEEDWERX MUFFLER, 9 lb 7 oz, 4000 69 dB, WOT 86 dB EngSpd STPPwr STPTrq BSFA_B FulA_B AFRA_B Air_1s ExhPrs Exh_2 RPM CHp Clb-ft lb/hph lbs/hr Ratio SCFM psig deg F

6700 115.4 90.5 0.586 65.7 13.47 193.3 2.1 9186800 116.9 90.3 0.597 67.7 13.41 198.4 2.1 9266900 119.3 90.8 0.615 71.3 13.27 206.6 2.3 9347000 122.4 91.9 0.623 74.1 13.13 212.5 2.4 9417100 125.3 92.7 0.634 77.2 12.96 218.4 2.5 9467200 128.0 93.4 0.643 80.0 12.78 223.3 2.7 9517300 132.4 95.2 0.658 84.5 12.51 231.0 2.9 9597400 138.4 98.2 0.659 88.6 12.27 237.4 3.0 9707500 143.9 100.8 0.657 91.8 12.08 242.3 3.0 9787600 148.3 102.5 0.655 94.4 11.95 246.5 3.1 9887700 151.6 103.4 0.653 96.2 11.89 249.9 3.2 9967800 154.4 104.0 0.648 97.1 11.93 253.1 3.3 10087900 156.5 104.0 0.642 97.5 12.01 255.7 3.3 10208000 157.5 103.4 0.639 97.6 12.10 257.9 3.3 10308100 156.4 101.4 0.645 97.9 12.15 259.9 3.3 10368200 152.3 97.6 0.660 97.6 12.23 260.7 3.1 10348300 140.2 88.7 0.707 96.1 12.38 259.8 3.0 1022

MBRP MUFFLER, 6 lb 13 oz, 4000 70 dB, WOT 86 dB EngSpd STPPwr STPTrq BSFA_B FulA_B AFRA_B Air_1s ExhPrs Exh_2 RPM CHp Clb-ft lb/hph lbs/hr Ratio SCFM psig deg F

6700 114.6 89.8 0.585 65.1 13.87 197.2 1.5 9106800 116.0 89.6 0.598 67.2 13.78 202.4 1.7 9186900 118.4 90.1 0.617 70.8 13.61 210.5 2.0 929

7000 121.3 91.0 0.625 73.5 13.49 216.6 2.0 9377100 123.9 91.7 0.638 76.7 13.32 223.2 2.2 9447200 126.6 92.4 0.649 79.7 13.12 228.4 2.3 9507300 130.6 94.0 0.661 83.7 12.86 235.3 2.5 9597400 138.2 98.1 0.662 88.7 12.56 243.3 2.6 9757500 144.3 101.1 0.654 91.5 12.39 247.7 2.5 9867600 149.0 103.0 0.651 94.0 12.25 251.5 2.6 9987700 152.1 103.8 0.651 96.0 12.14 254.4 2.8 10077800 154.0 103.7 0.651 97.2 12.08 256.7 2.8 10167900 154.6 102.8 0.651 97.5 12.14 258.6 2.8 10258000 153.6 100.8 0.654 97.4 12.24 260.3 2.7 10298100 150.0 97.3 0.672 97.6 12.26 261.4 2.6 10288200 136.2 87.3 0.739 97.5 12.20 259.9 2.5 10148300 122.6 77.6 0.805 95.5 12.42 259.0 2.4 10008400 113.7 71.1 0.843 92.6 12.47 252.3 2.1 996

SLP MUFFLER, 8 lb 11 oz, 4000 72 dB, WOT 88 dB EngSpd STPPwr STPTrq BSFA_B FulA_B AFRA_B Air_1s ExhPrs Exh_2 RPM CHp Clb-ft lb/hph lbs/hr Ratio SCFM psig deg F

6700 115.0 90.1 0.590 66.1 13.90 200.7 1.7 8786800 116.5 90.0 0.601 68.2 13.85 206.2 1.8 8896900 119.7 91.1 0.609 71.0 13.82 214.4 1.9 9037000 123.3 92.5 0.610 73.2 13.75 220.1 2.0 9157100 126.5 93.5 0.616 75.9 13.63 225.9 2.0 9257200 129.1 94.2 0.626 78.7 13.45 231.2 2.2 9337300 133.1 95.7 0.639 82.8 13.18 238.3 2.4 9447400 139.1 98.7 0.644 87.2 12.87 245.1 2.4 9597500 145.3 101.7 0.639 90.4 12.66 249.9 2.2 9727600 150.3 103.8 0.636 93.0 12.49 253.8 2.3 9847700 153.5 104.7 0.637 95.1 12.36 256.8 2.6 9957800 155.3 104.6 0.638 96.3 12.32 259.2 2.7 10057900 156.0 103.7 0.639 96.9 12.34 261.2 2.8 10148000 154.8 101.7 0.646 97.3 12.39 263.2 2.8 10208100 147.6 95.7 0.680 97.5 12.38 263.7 2.6 10168200 127.8 81.8 0.772 95.7 12.46 260.5 2.3 9918300 113.1 71.6 0.848 93.0 12.44 252.8 2.1 977

BMP TRAIL MUFFLER, 6 lb 11 oz, 4000 80 dB, WOT 87 dB EngSpd STPPwr STPTrq BSFA_B FulA_B AFRA_B Air_1s ExhPrs Exh_2 RPM CHp Clb-ft lb/hph lbs/hr Ratio SCFM psig deg F

6700 115.2 90.3 0.589 66.0 13.69 197.3 1.6 9116800 116.6 90.0 0.602 68.3 13.62 203.0 1.9 9186900 119.2 90.7 0.617 71.5 13.60 212.5 2.1 9307000 122.1 91.6 0.620 73.6 13.55 218.0 2.2 9387100 124.8 92.3 0.626 76.0 13.45 223.2 2.3 944

7200 127.4 92.9 0.638 79.0 13.28 229.2 2.4 9507300 130.9 94.2 0.647 82.4 13.07 235.0 2.5 9587400 137.1 97.3 0.654 87.2 12.75 242.9 2.9 9727500 143.7 100.6 0.648 90.5 12.55 248.0 3.3 9847600 148.7 102.7 0.644 93.1 12.39 251.9 3.3 9967700 152.2 103.8 0.644 95.3 12.24 255.0 3.0 10067800 154.4 104.0 0.643 96.5 12.21 257.3 2.9 10167900 155.7 103.5 0.640 96.8 12.26 259.3 2.9 10248000 155.4 102.0 0.643 97.0 12.33 261.4 2.9 10308100 152.9 99.1 0.654 97.1 12.40 263.2 2.9 10328200 146.5 93.8 0.677 96.2 12.53 263.4 2.7 10308300 132.9 84.1 0.730 94.1 12.77 262.5 2.6 10208400 121.7 76.1 0.749 88.4 12.62 243.7 2.4 1015

BMP POWDER LITE MUFFLER, 5 lb 0 oz, 4000 79 dB, WOT 92 dB EngSpd STPPwr STPTrq BSFA_B FulA_B AFRA_B Air_1s ExhPrs Exh_2 RPM CHp Clb-ft lb/hph lbs/hr Ratio SCFM psig deg F

6600 114.6 91.2 0.571 63.9 13.85 193.2 1.9 8866700 115.4 90.5 0.580 65.3 13.74 196.1 2.3 9036800 117.1 90.4 0.593 67.7 13.60 201.2 2.2 9126900 120.0 91.3 0.605 70.7 13.44 207.7 2.3 9227000 123.1 92.3 0.610 73.2 13.32 213.0 2.3 9327100 125.3 92.7 0.625 76.3 13.14 219.0 2.4 9397200 127.5 93.0 0.634 78.8 12.97 223.2 2.5 9427300 132.0 95.0 0.654 84.1 12.66 232.5 2.8 9527400 137.9 97.8 0.652 87.6 12.46 238.4 3.0 9627500 143.2 100.3 0.651 90.8 12.28 243.7 3.3 9727600 147.5 101.9 0.650 93.3 12.17 248.1 3.4 9807700 151.1 103.0 0.647 95.2 12.11 251.9 3.3 9917800 153.7 103.5 0.644 96.3 12.12 254.9 3.2 10017900 155.2 103.2 0.640 96.6 12.19 257.4 3.2 10098000 155.0 101.7 0.641 96.7 12.30 259.8 3.1 10168100 152.9 99.1 0.650 96.7 12.38 261.5 3.0 10188200 145.8 93.4 0.679 96.2 12.45 261.6 2.9 10148300 129.5 81.9 0.746 93.8 12.67 259.6 2.7 10028400 118.6 74.2 0.752 86.6 12.47 235.9 2.4 999

After comparing the mufflers on the bone stock ZR8000, Jim and Darren installed the 2 degree offset timing key, higher flowing Y pipe, LCR head (tighter squish clearance, lower compression ratio), and adjustable muffler included in the D&D “Riot” kit. We made best power with the adjustable outlet in the tightest position. How can we make more HP with less compression? The Cat deto protection is very sensitive—one or two light clicks on the dyno or in the field will result in timing being retarded, protecting the engine and reducing HP. D&D’s LCR head’s reduced compression head allows for advanced timing to bring back the peak cylinder pressure at the correct time ATC without deto. And remember—whatever air/fuel mixture is packed into an oversize squish band under compression will burn eventually, but too late to add to HP. Tightening the squish band squeezes more of that wasted mixture at high velocity into the combustion chamber allowing it to burn at the correct time, adding to HP. And, the increased velocity has the added benefit of increasing turbulence in the combustion chamber, which is said to cause the A/F mixture to burn more quickly—which can reduce the time necessary to create maximum combustion chamber pressure. It’s the same effect as increasing ignition timing, but without the penalty of adding burn time to heat the combustion chamber surfaces. So with the D&D Riot kit the combo of the tighter squish band and 2 degree key may have the net effect on peak combustion chamber pressure as, say, a 3.5 degree key, but with less heat being absorbed by the combustion chamber surfaces which can = less chance of deto. Balancing compression ratio, squish design and clearance, and ignition timing to create maximum torque on a given octane can result in optimal performance. D&D RIOT KIT WITH STOCK PIPE EngSpd STPPwr STPTrq BSFA_B FulA_B AFRA_B Air_1s ExhPrs Exh_2 RPM CHp Clb-ft lb/hph lbs/hr Ratio SCFM psig deg F

6700 118.8 93.1 0.569 65.5 13.51 193.4 1.7 9056800 120.3 92.9 0.589 68.7 13.32 199.9 2.1 9206900 123.1 93.7 0.598 71.4 13.22 206.1 2.3 9307000 126.0 94.5 0.603 73.5 13.18 211.8 2.5 9367100 128.5 95.0 0.614 76.4 13.08 218.3 2.6 9427200 131.0 95.5 0.623 79.0 12.91 222.9 2.7 9467300 135.1 97.2 0.636 83.2 12.65 229.9 2.8 9547400 141.9 100.7 0.636 87.4 12.41 237.0 3.2 9667500 147.8 103.5 0.629 90.0 12.30 241.8 3.6 9747600 152.8 105.6 0.623 92.2 12.20 245.8 3.7 9837700 157.7 107.6 0.621 94.9 12.06 250.1 3.4 9977800 160.9 108.3 0.618 96.3 12.03 253.2 3.3 10097900 162.3 107.9 0.615 96.6 12.10 255.4 3.3 10188000 161.6 106.1 0.621 97.2 12.15 257.9 3.3 10278100 159.3 103.3 0.633 97.7 12.16 259.4 3.2 10308200 141.1 90.4 0.714 97.4 12.01 255.5 2.9 10088300 126.3 79.9 0.763 93.1 11.49 233.8 2.6 990

Next Jim and Darren installed their D&D single pipe on the Riot kitted engine. They had to add fuel with their new Boondocker fuel controller, which now has more precise steps adds and subtracts fuel based upon % of fuel flow which is the ideal way to tune EFI very much like the DynoJet Power Commanders do. Then, they installed the full Jaws exhaust system—Y pipe with larger outlet and donut, single pipe and muffler. After creating good fuel maps for both systems, the full Jaws setup matched the D&D full system HP within a few tenths of a HP, but Jaws backpressure was lower. Jim installed the Speedwerx muffler on the Jaws pipe, and backpressure increased along with HP. The Jaws/ Speedwerx combo had a slight high RPM HP advantage but the D&D had better midrange torque and HP as the Riot graph comparing stock, D&D, and Jaws/ Speedwerx combo indicates. Jim and Darren plan to run their identical ZR8000s with Riot kits—one will have the D&D full exhaust with better midrange TQ and HP, and the other will have the higher RPM Jaws Ypipe and single pipe and Speedwerx muffler with the stock muffler insulation fitted to it to fool the SS (Schutzstaffel) Trail Police who like to lift hoods even on quiet sleds and write $200 tickets for “non OEM muffler”. RIOT KIT WITH D&D SINGLE PIPE EngSpd STPPwr STPTrq BSFA_B FulA_B AFRA_B Air_1s ExhPrs Exh_2 RPM CHp Clb-ft lb/hph lbs/hr Ratio SCFM psig deg F

6600 110.3 87.8 0.590 63.4 13.25 183.7 1.7 9246700 111.3 87.2 0.595 64.6 13.35 188.3 1.8 9336800 112.8 87.1 0.607 66.7 13.35 194.6 2.0 936

6900 115.8 88.2 0.620 69.9 13.33 203.5 2.3 9387000 120.8 90.6 0.621 73.1 13.28 212.0 2.3 9417100 124.4 92.0 0.628 76.1 13.14 218.3 2.4 9447200 127.8 93.2 0.631 78.5 12.99 222.8 2.6 9487300 135.2 97.2 0.638 83.9 12.67 232.4 2.9 9627400 142.7 101.3 0.627 87.0 12.50 237.7 3.0 9757500 152.4 106.7 0.612 90.8 12.31 244.0 3.1 9947600 158.6 109.6 0.604 93.2 12.20 248.2 3.3 10097700 162.6 110.9 0.599 94.7 12.15 251.4 3.4 10207800 166.0 111.8 0.593 95.7 12.21 255.3 3.3 10337900 167.6 111.4 0.589 96.1 12.33 258.7 3.4 10408000 156.2 102.6 0.636 96.5 12.23 257.7 3.2 10268100 133.0 86.2 0.733 94.7 11.57 239.3 2.7 994

RIOT KIT WITH JAWS Y PIPE, PIPE AND SPEEDWERX MUFFLER EngSpd STPPwr STPTrq BSFA_B FulA_B AFRA_B Air_1s ExhPrs Exh_2 RPM CHp Clb-ft lb/hph lbs/hr Ratio SCFM psig deg F

6700 112.5 88.2 0.573 62.3 13.38 182.1 1.9 9006800 114.0 88.0 0.587 64.8 13.19 186.8 2.0 9126900 116.3 88.6 0.602 67.8 12.99 192.4 2.1 9267000 119.7 89.8 0.612 70.9 12.83 198.9 2.2 9397100 122.2 90.4 0.623 73.7 12.68 204.1 2.3 9447200 124.7 91.0 0.635 76.6 12.52 209.5 2.5 9487300 129.2 93.0 0.647 80.9 12.33 217.8 2.7 9587400 135.8 96.4 0.644 84.7 12.17 225.1 2.9 9737500 141.6 99.1 0.643 88.1 12.03 231.4 3.0 9867600 145.7 100.7 0.641 90.2 11.95 235.6 3.1 9957700 150.6 102.7 0.637 92.8 11.85 240.2 3.2 10067800 156.1 105.1 0.630 95.1 11.79 245.0 3.2 10207900 159.9 106.3 0.622 96.2 11.84 248.8 3.3 10298000 163.9 107.6 0.616 97.6 11.90 253.8 3.4 10418100 167.4 108.5 0.614 99.2 11.92 258.4 3.4 10528200 169.5 108.6 0.614 100.6 11.99 263.3 3.4 10618300 170.1 107.6 0.614 100.8 12.15 267.7 3.5 10658400 169.0 105.7 0.618 100.8 12.32 271.2 3.5 10688500 155.6 96.1 0.675 101.3 12.19 269.6 3.5 1059

Here’s a graph of the HP of the three exhaust systems, with much finer resolution showing the exact shape of each curve. Sometimes recording 1,000 data points in a 10 second test provides a more meaningful picture of an engine’s HP curve.