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Old 05-09-2005, 06:45 PM   #1
Surly OP
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Location: Salem, OR
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WINGS Exhaust Install and Review

First impressions:

I opened the box and saw a nicely finished exhaust.


The muffler has polished stainless steel end caps affixed with stainless steel rivets and an anodized, brushed center section.


My particular muffler came with the orange/black Wings logo that I love because my 640 is orange.
(Baja dirt sold seperatly)


An added bonus with the muffler was the included (installed) sound restrictor/ spark arrestor. I ran my entire trip (3500+ miles) with this in place


You will also find a muffler clamp, soap solution and connecting pipe. The connecting pipe is needed because of the mammoth size of the stock exhaust dwarfs the Wings replacement


I don’t have weights for the new pipe as I got a little excited...


Installation:

For the install I removed the seat, plastic side panel, the three muffler hangers and two springs.


Keep and eye on those springs when you remove them or use a spring tool!


Remove the stock exhaust and you have something like this


I attached the connecting pipe first with both springs. The first spring is easiest because you may move the pipe in that direction. The second spring is where you may want a helper to push the pipe in the direction of the connectors so you don’t have to over stretch it. Better yet use a spring tool!


I then attached one hanger to the connector and rear sub frame. Slid the wide clamp over the muffler and the muffler over the connector pipe.
You may want to consider where the Allen head is facing should you need to tighten the clamp, with the plastic on the bike, after you have ridden the bike a few miles


Then the band and last hanger are attached. Note that both ends of the band go on the outside of the hanger


You will have one stock exhaust hangers left over.



Drink your beer or ginger ale and pat the dogs for not getting in the way.
Now GO RIDE!


Ride impressions:

My bike is a 2005 KTM 640 Adventure. When I installed the exhaust I had 400 miles on the clock and was leaving for Baja. Other related modifications were a 157.5 main-jet and racing air box cover.
I live at 4300 feet and this works very well but I intend to refine the jetting settings on the dyno soon

My trip consisted of interstate, secondary roads, miles of rough dirt and some asphalt that was worse than the dirt. I operated the bike at many different throttle openings with and without the 77lbs of gear I had with me. The power band seems smoother, less abrupt, and yet it pulls noticeable stronger all over the power band.

I have removed the restrictor/spark arrestor and the bike is noticeable louder but it pulls even better down low. I like it best this way and plan to leave it out.

So far I have 3600+ miles on the exhaust and I have had:

No leaks
No corrosion
No change in sound to indicate repacking needed
No problems

Granted its exhaust what could go wrong? Well there are less than good quality products out there. This one stands above.


Summary:

I love the sound. I love the appearance. I love the way the bike feels. I love my Wings
Consider this review a thumbs-up and a solid recommendation!


For more information you can contact Adventurers workshop
http://www.adventurersworkshop.com/
AFekete
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Old 05-09-2005, 06:50 PM   #2
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Just in case I didnt include enough...

mo' pics here
http://surly.smugmug.com/gallery/525813
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Old 05-09-2005, 09:47 PM   #3
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Thanks for the info - thinking of getting some myself
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Old 05-09-2005, 10:43 PM   #4
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Quote:
Originally Posted by Surly
I love the sound. I love the appearance. I love the way the bike feels. I love my Wings
Consider this review a thumbs-up and a solid recommendation!
Thanks for the vote of confidence
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Old 06-30-2005, 01:14 PM   #5
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Not to cause any problems here but did either of you guys have ANY problems mating the extention piece to the existing head pipe?

I just got mine and I either have to 1) sand off a few thou on the head pipe "bulge" or 2) beat the shit out of it. Neither one is appealing.

Just curious if this is a one off problem or not.

Gerg
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Old 06-30-2005, 01:26 PM   #6
Surly OP
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Quote:
Originally Posted by Gerg
Not to cause any problems here but did either of you guys have ANY problems mating the extention piece to the existing head pipe?

I just got mine and I either have to 1) sand off a few thou on the head pipe "bulge" or 2) beat the shit out of it. Neither one is appealing.

Just curious if this is a one off problem or not.

Gerg
nope
not a bit of trouble
the flange should fit right over the headpipe
sure you dont have something backwards?
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Old 06-30-2005, 01:46 PM   #7
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Quote:
Originally Posted by Surly
nope
not a bit of trouble
the flange should fit right over the headpipe
sure you dont have something backwards?
It'll only go one way
After closer scrutiny I think it's the wrong connector pipe. There is no way the hanger will reach if it was to slip on to the head pipe. Also, judging by the gouge marks on the head pipe I need about .010 more bell or smaller head pipe to fit. That's a lot.

I'll get some pictures later.

Gerg
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Old 06-30-2005, 08:53 PM   #8
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No pics but the calipers say I need .020 more bell on the connector pipe to fit. That's not happenin'... DARN!
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Old 06-30-2005, 11:00 PM   #9
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Thumb connector pipe....

Quote:
Originally Posted by Gerg
No pics but the calipers say I need .020 more bell on the connector pipe to fit. That's not happenin'... DARN!
Greg,

I just finished a LF 170/ Terranova bar installation so I was pretty tied up.

I will send a few more your way to see what happened. We'll get it straight.

thanks,
Andrew
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Old 06-30-2005, 11:35 PM   #10
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USFS Approved Sparky?

Is the Sparky USFS approved?
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Old 07-03-2005, 08:32 AM   #11
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Quote:
Originally Posted by soloyosh
Is the Sparky USFS approved?

Correct me if I am wrong Andrew, but it is not USFS approved (I have the Ti model) and there is no stamp. However, I just got in from playing around up here in Tahoe and a Ranger and I spoke about the pipe - no stamp, but the Ranger gave it the
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Old 07-03-2005, 08:34 AM   #12
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Quote:
Originally Posted by Gerg
Not to cause any problems here but did either of you guys have ANY problems mating the extention piece to the existing head pipe?

I just got mine and I either have to 1) sand off a few thou on the head pipe "bulge" or 2) beat the shit out of it. Neither one is appealing.

Just curious if this is a one off problem or not.

Gerg
I agree that you must have the wrong pipe by accident. My pipe went on flawlessly as nicely sorted out part shoud
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Old 07-18-2005, 06:42 PM   #13
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Update: Still no resolution so it's going back. Too bad, looks nice but it will not fit. Someone else ran into the same problem with an '05 so it isn't just me. $400 just laying around is just too much with no solution in sight.

Gerg
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Old 07-19-2005, 10:22 AM   #14
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Quote:
Originally Posted by Gerg
Update: Still no resolution so it's going back. Too bad, looks nice but it will not fit. Someone else ran into the same problem with an '05 so it isn't just me. $400 just laying around is just too much with no solution in sight.

Gerg
Too bad brotha...

I am still absolutely lovin' mine.

Too bad about the fit.
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Old 07-19-2005, 11:39 AM   #15
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minor problem overcome

First post but have been lurking and getting great information from this site. By the way, thanks to all the regulars who have helped me so much with making my new 640 Adv. a much better bike.

Ordered Wings silencer and found same problem as Gerg. Connector pipe didn't want to fit. Called Andrew to see if he knew how Gerg had resolved the problem - no information. Went back out to the barn and checked with micrometer: new connector pipe slightly ovoid in shape at upstream end. Can't remember the exact dimensions but not much.

Grabbed the special tool from the toolbox - two pieces of wood and the bmfh (large hammer) and proceeded to make the intake end of the connector pipe a little more round. Being careful not to pound the pipe into a shiny metal pancake, I really don't know if the special tool made much difference but the situation was improved.

Followed up with dremel tool on inside of connector pipe and outside of exhaust pipe. Took a little effort to put the two together but they fit together snugly. Finished jetting carb, airbox mods, etc. and took her for a ride in the mountains Sunday.....What a difference!

Anyway, there may be a tolerance issue on some bikes and Andrew probably needs to look into the manufacture of the connector pipes but the issue was easily resolved and I really like the new pipe. Thanks to Andrew for responding so well and offering to return the pipe or send additional coonectors to try.
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