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This job is not something you can easily tackle if you don't have access to an engineering workshop or a similar set up at home. Ideally you need a lathe (not essential though) and a welder, preferably of the TIG type if you want a neat job.
Regardless of that, here's a little how-to:
Remove the slip on and then the header pipe once you have uncliped the connection for the O2 sensor. Easily accessed on the RH side once fairings are removed. The nuts that hold the header pipe flanges on take a 12mm socket and are not tight because there is a compressible washer between the exhaust ports of the head and the two pipes.
Score a line at 90 degrees across the weld that joins the rear piece of the header (the bit that goes to the muffler) onto the main body that houses the CAT. You will use this line as a reference for when you go to weld the assembly back together again. Now cut through the weld with a hack saw or even better use a 1mm wide cut-off disc in an angle grinder if you have one.
At this stage you can now try and remove the CAT material but I found it too difficult so cut the front part of the header off from the main body as well:
This enabled me to hold the canister in the chuck of a lathe and drill a 1" hole through it:
That gave me enough room to get a boring bar in there and bore the rest of the CAT material out:
By using a lathe you end up with a nice clean job. There are actually two CATs in there, separated by a 3/4 inch gap. I turned the body around in the lathe to get at each end.
Then I spot welded the front header section back to the main body and fitted it to the bike. The slip on was next fitted to the bike with the rear section of the header slipped inside it. This allowed me to line everything up before finally putting a couple of careful spot welds on the rear join of the body. I used a gas welding plant for this so there were no sparks but you need to be real careful where you wave that torch! Have a fire extinguisher sitting right beside you.
Lastly I removed the whole assembly as one piece again ready to be fully TIG welded. I will get a mate of mine to do this as he's neater at it than me
There is bang on one lb (450 grams) of CAT material in there.
*
Regardless of that, here's a little how-to:
Remove the slip on and then the header pipe once you have uncliped the connection for the O2 sensor. Easily accessed on the RH side once fairings are removed. The nuts that hold the header pipe flanges on take a 12mm socket and are not tight because there is a compressible washer between the exhaust ports of the head and the two pipes.


Score a line at 90 degrees across the weld that joins the rear piece of the header (the bit that goes to the muffler) onto the main body that houses the CAT. You will use this line as a reference for when you go to weld the assembly back together again. Now cut through the weld with a hack saw or even better use a 1mm wide cut-off disc in an angle grinder if you have one.

At this stage you can now try and remove the CAT material but I found it too difficult so cut the front part of the header off from the main body as well:

This enabled me to hold the canister in the chuck of a lathe and drill a 1" hole through it:

That gave me enough room to get a boring bar in there and bore the rest of the CAT material out:

By using a lathe you end up with a nice clean job. There are actually two CATs in there, separated by a 3/4 inch gap. I turned the body around in the lathe to get at each end.

Then I spot welded the front header section back to the main body and fitted it to the bike. The slip on was next fitted to the bike with the rear section of the header slipped inside it. This allowed me to line everything up before finally putting a couple of careful spot welds on the rear join of the body. I used a gas welding plant for this so there were no sparks but you need to be real careful where you wave that torch! Have a fire extinguisher sitting right beside you.
Lastly I removed the whole assembly as one piece again ready to be fully TIG welded. I will get a mate of mine to do this as he's neater at it than me

There is bang on one lb (450 grams) of CAT material in there.
*